Home

Service Manual Outline

1. ES 54865 a Oil Pump b Output Hose Tee Fitting Flow specifications are as follows 660 RPM 25 6 cc 1096 in 30 min 1500 RPM 20 2 cc 1096 in 10 min 2500 RPM 33 6 cc 1096 in 10 min 5500 RPM 74 2 cc 10 in 10 min 90 814676R1 DECEMBER 1996 p i I Warning Module moval Disconnect engine battery cables from battery Verify ignition key is in OFF position Remove top cowl Remove 6 attaching bolts from electrical access cover and remove cover H 54645 90 814676R1 DECEMBER 1996 Disconnect warning module PURPLE TAN and both BLUE leads from their respective bullet con nectors Remove warning module BLACK ground lead from the upper right switch box mounting bolt Remove 2 bolts which secure warning module to electrical box and remove module 54866 a Switch Box Mounting Bolt remove Black Lead b Warning Module Bolts OIL INJECTION SYSTEM 8 9 Installation 1 Connect warning module PURPLE TAN and both BLUE leads to their respective bullet con nectors Secure warning module BLACK ground lead to upper rig
2. 54649 a Trigger Leads b Switch Box 8 If trigger is defective remove and retain link rod from trigger ELECTRICAL AND IGNITION 2A 21 f Trigger Plate Assembly Installation 4 Reconnect trigger wires to proper terminals of switch box Refer to wiring diagram Section 2D 1 Iflink rod was removed from trigger reassemble Torque terminal nuts to 30 Ib in 3 4 N m to trigger 2 Place trigger plate assembly in upper end cap Fasten link rod swivel to spark arm lever with lock nut 3 Route and secure trigger harness as shown 54649 a Trigger Harness b Switch Box 5 Reinstall electrical box access cover and secure cover with 6 bolts 6 Reinstall stator as outlined STATOR AS a Lock Nut SEMBLY INSTALLATION previously b Link Rod Swivel C Spark Arm 7 Reinstall flywheel as outlined in FLYWHEEL d Trigger Plate Assembly INSTALLATION previously e Sta Straps f Trigger Harness Route as Shown 8 Reinstall rewind starter if manual start or flywheel cover if electric start On either manual or electric models rewind or cover attaching bolts should be torqued to 100 Ib in 11 3 N m 9 Reinstall top cowl 2 22 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Ignition Coil Removal 1
3. a Lifting Eye 91 75132 POWERHEAD 4 13 Manual Start Model 1 Disconnect any alternator charging leads from battery Remove top cowl Remove spark plug leads from spark plugs 4 Unlatch cable retainer and remove throttle cable from throttle spark arm and shift cable from shift bracket 26830 a Throttle Cable b Throttle Cable Latch 5 Remove bolt securing fuel connector to bottom cowl 54674 a Bolt b Fuel Connector 4 14 POWERHEAD 6 Disconnect BLACK YELLOW stop leads both bullet connectors 7 Remove three black leads from grounding bolt at aft starboard corner of bottom cowl 8 Remove tell tale hose from bottom cowl Black Yellow Leads Bullet Connectors Black Leads Bolt Tell Tale Hose Remove bolt and retaining clip from anti start in gear linkage 54676 b Retaining Clip 10 Remove two fuel hoses from enrichener valve 54677 a Fuel Hoses b Enrichener Valve 90 814676R1 DECEMBER 1996 fn 11 Remove three bolts securing recoil starter to 13 Remove eight nuts securing powerhead to drive powerhead and remove recoil assembly shaft housing 26815 a Nuts 4 Each Side 14 Remove plastic cap from center of flywheel and thread lifting eye 91 75132 into flywheel Using hoist lift powerhead from driveshaft housing and install on powe
4. 50 6 Leaks Past and Seat Piston Assembly 5D 6 Troubleshooting Flow Diagram 5D 7 Troubleshooting Flow Diagram 5D 8 Electrical System Troubleshooting 5D 9 Commander 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5D 9 Power Trim System Wiring Diagram 5D10 Troubleshooting the Down Circuit When Up Circuit is OK 5D 11 Troubleshooting the Up Circuit When Down Circuit Is OK 5D 12 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5D 13 Page Power Trim System Removal 5D 14 Power Trim System Disassembly 5D 15 Trim Rod 5D 15 Trim Rod Disassembly 5D 16 Trim Motor Removal 5D 18 Trim Motor Disassembly 5D 18 Reservoir Assembly Removal 5D 18 Manifold Removal 5D 19 Cleaning and Inspection of Trim Rod Components 5D 20 Motor and Electrical Tests Repair 5D 20 Trim Pump Motor 5D 20 Armature Tests 5D 20 Test for Shorts 5D 20 Test for Ground 5D 20 Checking and Cleaning Commutator 50 21 Power Trim System Reassembly 5D 21 Manifold Ins
5. a Bolt 54680 Throte Spark Control Arm a Bolts Torque to 150 Ib in 16 9 N m b Throttle Actuator Assembly 27 Referring to Section 3 reinstall carburetors fuel pump and fuel enrichment components 28 Referring to Section 2 reinstall ignition compo nents and flywheel 29 On Electric Start Models reinstall starter motor referring to Section B 90 814676R1 DECEMBER 1996 POWERHEAD 4 47 Installing Powerhead Driveshaft Housing 1 Verify gearcase is in neutral propeller shaft turns freely in both directions Shift lever plate should be positioned as shown with gearcase in neutral 2 Inspect powerhead base gasket surface on both driveshaft housing and bottom of powerhead for cleanliness and roughness Both surfaces MUST BE clean and smooth 3 Install new powerhead base gasket on driveshaft housing Apply 2 4 C Marine Lubricant to drive shaft splines DO NOT apply grease to the top of the driveshaft as this will prevent driveshaft from fully engaging crankshaft a Shift Lever Plate b Gasket Driveshaft Splines 4 Thread LIFTING EYE 91 75132 into flywheel at least 5 full turns 4 48 POWERHEAD 5 Using suitable hoist install powerhead onto driveshaft housing NOTE It may be necessary to rotate flywheel slightly to engage crankshaft splines into driveshaft splines when lowering
6. um wm D BLK YEL rn BLK YEL 4 O STOP SWITCH TO BOTTOM COWL 50503 2D 10 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 aX Wiring Diagram Model 40 Manual Start with Red Stator BLK Black BLU Blue BRN Brown lt a GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red Tan Tan WHT White YEL Yellow LIT Light DRK Dark 54948 Lighting Coil Stator BLUE WHITE Lead Not Used Plug Terminal Block Stator Adaptor Switch Box Ground Connection 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 11 Power Trim Wiring Diagram UP TRIM SOLENOID DOWN TRIM SOLENOID vu TO BATTERY HE e RECTIFIER e 8C BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 2D 12 ELECTRICAL AND IGNITION BLU oc BLU 1 TRIM MOTOR 1 1 1 1 2 BLU WHT GRN WHT 20 AMP FUSE a COWL MOUNTED TRIM SWITCH 50516 90 814676R1 DECEMBER 1996 AA Commander 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram BLK 4 TAN BLU 3 TAN BLU C GRY B PUR 2 BLK D PUR A BLK YEL 1 BRN WHT E YEL BLK 6 YEL RED 7 RED 8
7. 22 Install cylinder cover and new gasket Torque bolts equally in three progressive steps to 100 Ib in 11 3 N m a Balance Tube b Fittings T Fitting Fuel Enrichment d Bleed Hose e Bleed Check Valve 20 Apply pipe sealant obtain locally to threads of 45 tell tale fitting and install fitting and hose a Oylinder Cover b Gasket c Bolt 10 Each a 45 Tell Tale Fitting 90 814676R1 DECEMBER 1996 POWERHEAD 4 45 23 Install temperature switch in cylinder block NOTE A plug is provided on cylinder cover which may be removed for installing a Water Pressure Gauge Kit or a Water Temperature Gauge Kit 50531 Cylinder Block Cover Torque Sequence 54692 a Plug Remove for Installation of Water Pressure or Water Temperature Gauge Kit b Temperature Switch 24 On Electric Start Models Only refer to Section 8 Oil Injection for proper installation procedure of oil pump 4 46 POWERHEAD 90 814676R1 DECEMBER 1996 n 25 Install throttle spark control arm assembly Se 26 Install throttle actuator assembly to crankcase cure control to cylinder block with bolt cover Secure actuator with three bolts Torque bolts to 150 Ib in 16 9 N m
8. 54636 a Compression Gauge P N 91 29287 90 814676R1 DECEMBER 1996 i 70 Procedures Cleaning amp Painting Aluminum Propellers amp Gear Housings Avoid serious injury from flying debris Avoid se rious injury from airborne particles Use eye and breathing protection with proper ventilation PROPELLERS 1 Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch Brite disc or belts 2 Feather edges of all broken paint edges Try not to sand through the primer 3 Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent Xylene or M E K 4 f bare metal has been exposed use Quicksil ver s Light Gray Primer 5 Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat 6 Apply the finish coat using Quicksilver s EDP Propeller Black GEAR HOUSINGS The following procedures should be used in refinish ing gear housings This procedure will provide the most durable paint system available in the field The materials recommended are of high quality and approximate marine requirements The following procedure will provide a repaint job that compares with a properly applied factory paint finish It is rec ommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet The minimum package quantity of each material shown following is suffi
9. 1 1 General Specifications 1 2 Propeller Selection 1 3 Propeller Installation 1 3 Trim Angle Adjustment 1 4 Power Trim System Models with Power o dace teet P RUE das 1 4 General Information 1 4 Checking Trim System Fluid Level 1 5 Trimming Models with Power Trim 1 5 Trimming Outboard Out Up Characteristics 1 5 Trimming Outboard In Down Characteristics 1 5 Trim Tab 1 6 Boat Performance 1 6 Test Instructions 1 6 Boat Test Chart Example 1 7 Lubrication Points 1 8 Ride Guide Steering Cable and Pivot Points Lubrication 1 9 Gear Housing Lubrication 1 10 Salt Water Corrosion Gear Housing Bearing Carrier and Cover Nut 1 10 Periodic Inspection 1 11 Flushing Outboard Cooling System 1 11 Following Complete Submersion 1 12 Salt Water Submersion Special 51 5 1 12 Submerged While Running Special 1 51 5 1 12 Submerged Engine Fresh Water Plus Special Instructions 1 12 Out of
10. 5E 1 Theory Of Operation 5E 4 Adjustments 5E 4 Trimming Characteristics 5E 4 Trimming Outboard Up Out 5E 4 Trimming Outboard Down In 5E 4 Trailering Outboard 5E 5 Tilting Outboard Up and Down Manually 5E 5 Tnm 522555552556 eee epee ees 5E 7 udi ceeds 5E 9 Maximum 11 Down 5E 13 Shock Function Up 5E 15 Shock Function Return 5E 17 Manual 5E 19 Troubleshooting 5E 20 Preliminary Checks 5E 20 Hydraulic System Troubleshooting Flow 5E 21 Hydraulic System Troubleshooting Flow 5E 22 Hydraulic System Troubleshooting Flow 5E 23 Hydraulic System Troubleshooting Flow 5E 24 Troubleshooting the Power Trim Electrical System Wiring Diagram 5 25 Troubleshooting the Power Trim Electrical System 5E 26 Page Power Trim System Removal 5E 27 Power Trim Disassembly 5E 28 Trim Motor Removal 5E 29 Pump and Components Removal 5E 29 Ma
11. 5C 20 Page Power Trim System Removal 5C 21 Power Trim System Disassembly 5C 22 Trim Rod 5C 22 Trim Rod Disassembly 5C 23 Trim Motor Removal 5C 25 Trim Motor Disassembly 5C 25 Reservoir Assembly Removal 5C 26 Oil Pump Manifold Removal 5C 27 Cleaning and Inspection of Trim Rod Components 5C 28 Motor and Electrical Tests Repair 5C 29 Trim Pump Motor 5C 29 Thermal Overload Switch Test 5C 29 Motor Assembled 5C 29 Motor Disassembled 5C 29 Armature Tests 5C 30 Test for Shorts 5C 30 Test for Ground 5C 30 Checking and Cleaning Commutator 56 30 Power Trim System Re assembly 5C 30 Manifold Oil Pump Installation 5C 30 Trim Motor Re assembly 5C 31 Reservoir Installation 5C 33 Trim Rod Re assembly 5C 34 Trim Rod Installation 5C 35 Bleeding Power Trim Unit 5C 36 Power Trim Unit Installation 5C 37 90 814676R1 DECEMBER 1996 p Power Trim General Information Description The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The remote control or
12. 2247 74 LIT Light me LE EM iN MG N e N N N N 4 N ba P N z N ES i N N 2 N S BN 23893 RUN OFF Switch b Emergency Stop Switch Stop Switch Harness 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 15 f Key Choke Switch Continuity Test Commander 2000 Side Mount Remote Control BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark OFF RUN START PUSH CHOKE 23894 BLK YEL BLK RED PUR RED PUR YEL RED RED YEL BLK Key switch must be positioned to RUN or START and key pushed in to actuate choke for this continuity test 2D 16 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Panel Mount Remote Control Wiring Diagram Sy GRN WHT 74 BLU WHT RED PUR BLK Black BLU Blue Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow 50148 LIT Light DRK Dark 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 17 Remote Key Switch and Warning Horn BLK Black BLU Blue Brown GRY Gray Green PNK Pink PUR Purple 4 WIR
13. 54820 45 Angle 1 8 Turn 54822 7B 2 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 90 814676R1 DECEMBER 1996 c Install throttle cable into tiller handle port until e Rotate drive rod counterclockwise 1 4 turn movement is felt in drive rod 90 until flat surface becomes parallel with work surface vy 54823 1 4 Turn d Rotate drive rod counterclockwise 1 8 turn 54823 45 until flat surface becomes parallel with work surface f Measure distance between tiller handle port and end of throttle cable A measurement of 18 in 457mm must be attained for throttle shutter plates to open and close properly ER EN N 7 7 2 54824 gt E K 1 8 Turn 54823 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7 3 g Install throttle handle to handle Align IDLE on throttle handle with arrow on tiller handle without moving drive rod Recheck 54825 IMPORTANT If 18 in 457mm measurement is not attained following throttle cable installation repeat steps a g zx J 54826 7B 4 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 6 Install washer nut and end cap to throttle grip Tighten nut snuggly allowing grip to turn freely 7 Install conduit a to ti
14. 2B 5 Alternator System Test 2B 5 Manual Start Models Stator Output TOS scidit Diei cds 2B 5 Electric Start Models With Rectifier 2B 5 Electric Start Models With Voltage Regulator Rectifier 2B 6 Rectifier 2 7 Starter System 2B 8 Starter System Components 2B 8 Description 2 8 Troubleshooting the Starter Circuit 2B 8 Starter Circuit Troubleshooting Flow GNAM 225 aai od geb haan a SURE ad Roa 2B 9 Starter Removal and Installation 2B 10 Removal io c deca Shae ER 2B 10 Installation 2B 10 Bosch 2B 11 Disassembly 2B 11 Starter Cleaning Inspection and Testing 2B 12 Cleaning and Inspection 2B 12 ERR DERE ERES 2B 12 Armature Test for Shorts 2B 12 Armature Test for Ground 2B 12 Checking Positive Brushes and Terminal 2 13 Testing Negative Brushes for Ground BOSOM noo adips eee baud 2B 13 Reassembly 2B 14 Starter Solenoid 2B 16 gt 90 814676R1 DECEMBER 1996 Battery Precautions When charging batteries an explosive hydrogen gas mixture forms in each cell Part of this gas es capes thru holes in vent plug
15. Loctite Grade 271 Plate 7 Gasket See Quicksilver Accessories Guide for part num 8 Screw 4 bers 9 Housing 10 Drive Rod 11 Throttle Cable 12 Conduit 13 Throttle Barrel 14 Tube 15 Screw 16 Guide 17 Anchor 18 Screw 2 19 Shift Lever 20 Knob 21 Bushing 22 Washer 23 Cotter Pin 24 Shift Rod 25 Rod End 26 Detent 27 Screw 2 28 Bushing 29 Washer 30 Screw 31 Washer 32 Bracket 33 Washer 34 Bushing 2 35 Spacer 36 Washer 37 Wave Washer 2 38 Washer 39 Locknut 40 Spacer 41 Stud 2 42 Tab Washer 2 43 Nut 2 44 Retainer 45 Stop Switch 46 Washer 47 Clamp 48 Lanyard Electric Start Models 49 Switch Assembly 50 Screw 2 51 Set Screw 2 52 Actuator Torque Specifications Q 30 Ib in 3 3 N m 33 Ib ft 45 N m 40 Ib in 4 4 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7B 1 cM Tiller Handle Throttle Cable buc a Position drive rod flat surface parallel to work Replacement 22 1 Remove tiller handle from outboard 2 Remove throttle twist grip 3 Loosen screws a securing cable guide b to throttle cable c 9 54821 54819 Drive Rod b Rotate drive rod either direction 1 8 turn to attain drive rod flat surface of 45 4 Remove conduit a and throttle cable from tiller handle
16. Shock Piston 55 8068 2021 53096 mm 0211 6394 mm 75 Piston Bok 06760 1717 mm 8161 G0726 mm 007m 78mm Ja 9 Rocumutator 277 5 69 mm 22541 5725 mm 007m 78 mm 10 lipseal 11 CamShaft 0 301 in 7 645 0 441 in 11 20 mm 0 07 in 1 78 mm 12 Back Up Ring 13 Surge Valve 0 801 in 645mm 0 444 in 1 20 mm 007 1 78 mm 14 Memory Piston 161 4064 2 02 in 63 086 mm 021 6 934 mm _ 5G 26 MID SECTION 90 814676R1 DECEMBER 1996 Manual Tilt System Cleaning and Inspection 1 is recommended that all O rings exposed dur ing disassembly be replaced 2 Clean components filter and check valve seats using engine cleaner and compressed air Do not use cloth rags 3 Inspectall machined surfaces for burrs or scoring to assure O ring longevity 4 Inspect shock rod If wiper located in cap has failed to keep rod clean replace wiper Manual Tilt System Reassembly IMPORTANT Components must be dirt and lint free Slightest amount of debris in tilt system could cause system to malfunction Apply Quicksilver Power Trim and Steering Fluid to all O rings during reassembly If not available use automotive ATF automatic transmission fluid CAM SHAFT REASSEMBLY IMPORTANT Cam shaft O ring must be lubri cated using 2 4 C with Teflon 92 825407A12 Install lubricated O ring and back up seal to cam Instal
17. a Rod End Retainer 90 814676R1 DECEMBER 1996 Shift Cable Adjustment The shift cable must be adjusted to lock the re verse gate against unexpected engagement caused by water pressure hitting the gate while operating the boat in forward Activation of the re verse gate will cause sudden unexpected stop ping of the boat Sudden stopping may cause oc cupants to be thrown within the boat or even out of the boat This action may result serious inju ry or death 1 Place shift lever into full forward position 2 Adjust the brass barrel on the shift cable so that roller is at the full end of travel bottom in the shift cam when the shift lever is in forward 3 Attach the brass barrel to the bracket with bolt and locknut Tighten the bolt until it seats against the barrel then back off the bolt 1 4 turn Hold bolt from turning and tighten locknut on bolt The bar rel must be free to pivot Shift Cable Shift Cam Barrel Roller Recheck the shift cable adjustment in forward shift position The correct shift adjustment will position the cam far enough on the roller in order to lock the the reverse gate into forward position You should not be able to forcibly push up the re verse gate toward neutral Pull on the reverse gate by hand to verify this IMPORTANT The forward locking of the reverse gate must be met If not readjust the shift cable LOWER UNIT 6B 19 OUTBOARD MOTOR
18. 6 Fasten outboard to the transom at this height LOWER UNIT 6B 5 SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH FLAT BOTTOM HULLS 1 Place center the outboard on the boat transom so that the transom brackets are resting on top of the transom Temporarily fasten the outboard to the transom using two C clamps 2 Position the outboard in a vertical position 3 Placeastraight edge along the bottom of the boat as shown and measure the distance between the bottom of the boat and top front edge of the water intake housing o Straight Edge Top Edge of Water Intake Housing 4 Raise the outboard up on the transom dis tance measured in Step 3 Use a straight edge and recheck the mounting height The top edge of the water intake housing should be in line with the bottom of the boat as shown c When operating boat the outboard drive shaft should be vertical when planing or tilted toward the boat in order to provide a scooping angle on the water intake Tilting the outboard out beyond a vertical posi tion reduces the scoop angle and can cause impeller slippage and cavitation If the angle of the boat tran som does not allow the drive shaft to be positioned vertically a Wedge kit should be installed behind the transom brackets to increase the tilt in angle NOTE Slight cavitation in sharp turns and rough wa ter is acceptable but excessive cavitation is harmful to the outboard and sho
19. Open and close cam lever watching for bubbles coming from accumulator check ball hole When bubbles stop fill accumulator opening to top with fluid Grease threads on accumulator and open ing with 2 4 C with Teflon Start accumulator in threads and open cam lever Down Position Torque accumulator to 35 Ib ft 47 N m 51143 a Accumulator b Cam Lever Down Position NOTE If filling procedure is done correctly it should be hard to turn cylinder rod assembly by hand 90 814676R1 DECEMBER 1996 Filling Procedure Option Two Instructions for Making Retaining Tool 3 16 in x 3 in 5 x 7 5 cm Steel Plate 3 8 in x 13 in 10mm x 33cm Threaded Rod f Ain x 1 4 in min 10cm x 6 4mm minimum Channel Iron 2 holes 7 16 in dia 11 mm 1 1 4 in 125mm gt 30m 20 in 508mm 4in 100 mm 3 8 in dia 2 holes 152mm 203mm 90 814676R1 DECEMBER 1996 MID SECTION 5G 31 2 in 50mm m Bleeding Manual Tilt System 3 Bleedunit by pushing rod down slowly 18 20 se conds per stroke until stopped at base Wait until IMPORTANT While bleeding tilt system time all air bubbles exit accumulator base must be allowed between each stroke to allow air bubbles to dissipate 1 With shock rod in the full up position and manifold cam lever open facing down secure tilt system to retaining tool and container A No 10 can or 3 Ib co
20. a Shock Piston b O ring c 5E 38 MID SECTION cM Position cylinder end cap onto rod as shown 4 Clamp shock rod in soft jawed vise e 51146 CAUTION When installing shock rod piston spanner wrench must 1 4 in x 5 16 in 6 4mm x8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod Install shock rod piston 8 Tighten shock rod piston securely using spanner wrench 1 4 in x 5 16 in long pegs If a torquing type spanner tool is used to tighten shock piston then torque to 90 Ib ft 122 N m 51146 a Shock Rod Piston Torque to 90 Ib ft 122 b Spanner Wrench 90 814676R1 DECEMBER 1996 p i 9 Remove shock rod assembly from vise 10 Install ball seat and spring five sets to shock rod piston 11 Secure components with plate Torque screws to 35 Ib in 4 0 Nm b 51147 Screws 3 Torque to 35 Ib in 4 0 Plate Springs 5 Seats 5 Balls 5 90 814676R1 DECEMBER 1996 Shock Rod Installation 1 Place trim cylinder in soft jawed vice 2 Install lubricated O ring to memory piston and place into cylinder Push memory piston all the way to bottom a Memory Piston b O ring 3 Fill cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steer ing Fluid If not available use automotive
21. v a Lubricate Shift Slider Rail With Quicksilver 2 4 C Multipur pose Lubricant with Teflon b Shift Slider Spacer 23 32 in Long d Bolt 1 3 4 in Long 6B 18 LOWER UNIT 16 Refer to the parts provided with your tiller handle kit and install the neutral start switch to the retain er Do not tighten screws at this time a Retainer b Neutral Start Switch Screw 2 Do Not At This Time d Locknut 2 17 Install retainer with two screws a Retainer b Screw 2 Provided With This Kit c Connect Ground Wire From Neutral Start Switch With Screw 18 Adjust the neutral start switch as follows a Place the outboard shift lever into neutral position b With the shift lever in neutral adjust the shift rod so that the flat lobe on the shift slider is centered with the roller on the neutral start Switch 90 814676R1 DECEMBER 1996 Loosen the upper mounting screw for the neu tral start switch Rotate the neutral start switch up then lower the switch until the roller acti vates the switch clicks Fasten switch at this position Shift Rod b Shift Slider Center Flat Lobe with Roller d Neutral Start Switch 19 Secure shift rod with rod end retainer
22. 4 28 Cleaning Connecting Rods 4 30 Crankshaft kre ony 4 30 Ball 4 31 Powerhead Reassembly 4 31 c r MT 4 31 Crankshaft 4 32 Piston Installation scere tre re 4 35 Crankshaft Seal Installation 4 37 End Cap Reassembly 4 38 Lower End 4 38 Upper End 4 39 Cylinder Block Reassembly 4 39 Installing Powerhead on Driveshaft HOUSING oid eR Ep arp qd Reed ark 4 48 90 814676R1 DECEMBER 1996 pa 1 Specifications Block 4 Oylinder 2 Cycle Displacement 44 0 cu in 721 cc Cylinder Bore Dia Standard 2 565 in 65 15 mm Dia 015 in Oversize 2 580 in 65 32 mm Dia 030 in Oversize 2 595 in 65 91 mm Out of Round Max 0 004 in 0 10 mm Taper Max 0 004 in 0 10 mm Piston Dia Standard 2 558 in 64 97 mm Dia 015 in Oversize 2 573 in 65 35 mm Dia 030 in Oversize 2 588 in 65 73 mm Piston Clearance 0 007 in to 0 011 in 0 17 mm to 0 27 mm Piston Ring End Gap 0 0015 in to 0 014 in 0 038 mm to 0 35 mm Reed Block Reed Stop Opening Max 0 020 in 0 50 mm Crankshaft Runout Max 0 003 in 0 08 mm Taper Max 0 003 in 0 08
23. 51078 a Tilt Tube b Fiber Washer Lock Nuts ee 51079 5 Apply Quicksilver 2 4 C Marine Lubricant to steering arm shaft and install a Washer b Yoke Snap Ring 7 Install lower mounting bracket to transom brack ets 51079 a Steering Arm b Washer 51079 a Lower Mounting Bracket b Bolt 90 814676R1 DECEMBER 1996 MID SECTION 5A 5 Drive Shaft Housing 1 2 Secure transom bracket assembly transom Install drive shaft housing to transom bracket as sembly Secure using bolts and components as shown Transom Bracket Assembly Drive Shaft Housing Bolts Lock Nuts Torque to 40 Ib ft 54 2 N m Washer Rubber Mount Washer 5A 6 MID SECTION 3 Secure lower mount assembly to drive shaft housing Secure drive shaft housing to yoke Lower Mount Assembly Ground Cable Bolt Torque to 150 Ib in 17 N m Lock Nut Torque to 60 Ib ft 81 3 N m 4 Install exhaust plate assembly to drive shaft housing using new exhaust plate gasket a Exhaust Plate Assembly b Drive Shaft Housing 90 814676R1 DECEMBER 1996 gearcase shift shaft in neutral position propeller shaft turns freely in both direction and install to mid section Refer to Section 6A 6 Insta
24. 51146 a Valve Block b Screws 2 Torque to 100 Ib in 11 N m c Shock Rod Oylinder 088 m Plungers 2 Steel Balls 2 Springs 2 O rings 2 Screw Plugs 2 Torque to 75 Ib in 8 5 N m aog 5G 28 MID SECTION 90 814676R1 DECEMBER 1996 c i Shock Rod Reassembly 1 Install lubricated O rings to end cap 2 Install rod wiper O b Y 51145 a Rod Wiper b Inner O ring c Outer O ring 3 Install lubricated O rings to shock piston 51199 a Shock Piston b O ring c O ring 4 Clamp shock rod in soft jawed vise 5 Position cylinder end cap onto rod as shown 51146 90 814676R1 DECEMBER 1996 A CAUTION When installing shock rod piston spanner wrench must have1 4 in x 5 16 in 6 4mm x8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod Install shock rod piston Tighten shock rod piston securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner tool is used to tighten shock piston then torque to 90 Ib ft 122 51146 a Spanner Wrench b Shock Rod Piston Torque to 90 Ib ft 122 9 Install ball seat and spring five sets to shock rod piston 10 Secure components with plate Torque screws to 35 Ib in 3 9 N m 11 Remove shock rod assembly from vise b 51147 a Sc
25. 8 7 Troubleshooting the Oil Injection System 8 7 Troubleshooting Chart 8 7 Installing Drive Gear for Oil Injection Pump Onto Crankshaft 8 8 Oil Pump Volume Flow Test 8 8 Oil Warning Module 8 9 Removal ud oa dE ack 8 9 Installation 8 10 Engine Mounted Reservoir 8 10 Removal Pr 8 10 Installation 8 11 90 814676 1 1996 Q Operation of the Oil Injection System The oil injection system delivers an oil mixture of 50 1 by means of a constant ratio oil pump The engine mounted oil reservoir holds 935 gal 3 54 Liters which will provide 7 hours of running time at wide open throttle A low oil warning buzzer will be activated when 7 5 fl oz 225ml of oil is left in the reservoir This will pro vide approximately 30 minutes of wide open throttle running before the oil is depleted The oil injection pump is driven by the crankshaft and feeds oil into the fuel before the fuel pump Oil Injection Components 1 Oil Reservoir The oil reservoir gravity feeds oil to the oil pump Oil reservoir contains a low oil sensor which acti vates a warning horn when 7 5 fl oz 225ml of oil is left in reservoir 2 Oil Injection Pump The oil injection pump is driven off of the crank shaft Itis a constan
26. Heading At Coil Coil Coil Coil Primary 400 160 250 180 275 275 ELM VOLTAGE 16 AMP STATOR 398 9710A33 amp 398 9710A42 Tested Part Selector Voltage Voltage Voltage Position 300 RPM 9 1000 RPM 9 4000 RPM Coil Coil Coil Primary 400 VDC 110 140 250 300 215 265 2 TEST RESULTS Good voltage output Go to STEP 3 Sta 20 YEL tor Low Speed and High Speed Test SG S e High voltage output The trigger or switch Lo box is defective Go to Trigger Test and 10 Lio test trigger If trigger tests OK replace DV 9 switch box and repeat step SM e No voltage output or low voltage output Remove BLK YEL wires from switch box terminal and repeat test If voltage output 1 Use Multimeter DVA Tester 91 99750 is now OK either the ignition switch stop switch or wiring is defective If no voltage 2 Crankengine and observe meter reading or low voltage remains go to STEP 5 Stator Low and High Speed Test IGNITION VOLTAGE 9 AMP STATOR Selector Reading At Reading At BI k Yell IGNITION VOLTAGE 16 AMP STATOR 398 9710A33 amp 398 9710A42 Selector Voltage Voltage Voltage Blac k Yellow 2A 4 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 a Igniti
27. 1 With boat in water trim the outboard s trim but ton in remote control handle so that the decal on the side of cowl is horizontal This is a typical av erage setting that should give reasonable accel eration and top speed 2 Go for a short familiarization ride at various throttle and trim settings BEFORE starting test ing NOTE Instruments should be read with eye directly in front to eliminate any error in reading the instru ments 3 When making either top speed or acceleration runs best accuracy will be obtained by running with or against any wind Side winds require driv ing in a constant turn to keep the boat moving straight ahead If winds are 10 MPH 16 km hr or greater it is suggested that all acceleration runs be made downwind 90 814676R1 DECEMBER 1996 p The top speed WOT wide open throttle test should be done with the boat normally loaded to duplicate actual running conditions Operate boat in gear at WOT and check RPM Engine RPM must be within the recommended full throttle RPM range listed in the Operation and Maintenance Manual NOTE When performing an acceleration test it is recommended that a stop watch be used to improve testing accuracy A wrist watch with a second hand may also be substituted 5 An acceleration test can also be performed if de sired Start the test with boat motionless in the water and outboard in neutral A stop watch should be started as the throttle
28. 2 Lubricate end cap bushing with Quicksilver 2 4 C Lubricant and install armature and motor frame into end cap As brushes contact commutator re a End Cap lease brush tension spring from ends of brush Motor Housing d 51485 5 Armature and Motor Frame housings returning springs to apply brush pres Washer One Each End of Armature sure to commutator Install washer on each end of armature before installing armature into end cap see inset 5D 22 MID SECTION 90 814676R1 DECEMBER 1996 cM Reservoir Installation 5 Secure reservoir to manifold using four screws Torque screws to 70 Ib in 7 7 N m 1 Torque end cap screws to 13 Ib ft 1 5 N m a Screws 4 6 Install lubricated O rings and E clip to manual release valve a End Cap b O ring c Screws 4 2 Place drive shaft into oil pump 3 Install lubricated O ring to base of reservoir 4 Carefully guide with motor down onto drive shaft a E Clip b O ring c Manual Release Valve 7 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 turns maximum allowing trim rod installation a Manual Release Valve b Manifold a Drive Shaft b O ring 90 814676R1 DECEMBER 1996 MID SECTION 5D 23 Trim Rod Reassembly 4 Apply Loctite Grade A 271 to threads of trim rod and install rod piston Tighten piston securely us 1 Install lubricated O r
29. L 50532 Exhaust Manifold Cover a Cylinder Block Cover b Temperature Switch T d E a Exhaust Manifold Cover b Baffle Plate C Gaskets 4 20 POWERHEAD 90 814676R1 DECEMBER 1996 Q End Cap Disassembly IMPORTANT is recommended that new oil seals be installed in end caps regardless of ap pearance to ensure lasting repair UPPER END CAP 1 Drive oil seal from end cap with a suitable punch Discard oil seal 2 Remove and discard O ring from end cap Seal Hidden Upper End Cap O Ring Punch 90 814676R1 DECEMBER 1996 3 Inspect ball bearing located in the end cap as out lined in Cleaning and Inspection following IMPORTANT DO NOT remove ball bearing from end cap unless replacement is required IMPORTANT It is recommended that heat be ap plied carefully to end cap housing to aid in re moval of ball bearing 4 lfinspection determines that replacement of ball bearing is required use Ball Bearing Puller 91 24100A1 and press ball bearing from end cap 55432 LOWER END CAP 1 Remove and discard O ring from end cap POWERHEAD 4 21 2 Use Ball Bearing Puller 91 24100 1 and press ball bearing from end cap Inspect ball bearing as outlined in Cleaning and Inspect
30. Replace defective valve and O Inspect Trim Rod Piston Check rings Valve Results Results No debris or defective components Debris found in check valve com found ponents Inspect Manifold Reverse Thrust Clean check valve components Valve using engine cleaner and com pressed air or replace Replace Pump and Manifold Assembly 5D 8 MID SECTION 90 814676R1 DECEMBER 1996 A 1 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram BLK 4 GRY 5 TAN BLU 3 TAN BLU C GRY PUR 2 BLK 0 PUR YEL BLK 6 YEL RED 7 BLK YEL 11 RED 8 Black Blue BRN Brown GRY Gray A GRN Green PUR Purple NS Red v TAN Tan WHT White YELe Yellow 07 Ignition Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer Accessories Harness Connector 23891 Wiring Harness Connector Warning Horn Trim Tilt Switch 90 814676R1 DECEMBER 1996 MID SECTION 5D 9 Power Trim System Wiring Diagram BLK Black Negative BLU Blue Trim Motor UP GRN Green Trim Motor DOWN RED Red Positive 4 Wiring From Side Mount Remote Control Harness BLU WHT Blue White Switch to UP Relay GRN WHT Green White Trim Switch to DOWN Re
31. Torque bolt to 90 Ib in 10 2 N m 51007 O rings 3 Oil Pump Screw Spring Check Ball Trim Motor Reassembly 1 Apply Quicksilver Marine Lubricant 2 4 C to ar mature shaft and insert into end frame 51007 a O ring b Screws 100 Ib in 11 3 N m 3 Secure power trim unit in soft jawed vise x q NA ATI a img Be gt MN mmi P i R N N 51195 a Armature Shaft b Washer c End Frame 90 814676R1 DECEMBER 1996 MID SECTION 5C 31 2 Guide armature and end frame into housing as 6 Install end cap to housing Torque nuts to 25 Ib shown in 2 8 N m End Cap Motor Housing Wave Washer Washer Qoo v 51196 3 Align scribe mark on housing to mark on end IMPORTANT When installing motor wires frame black orange must rest in cavity of cylinder al 4 Install lubricated O ring to end frame lowing motor to seat properly a 51194 51194 a O ring a Manifold b Scribe Mark b Cavity 5 Install washers to armature shaft as shown 5C 32 MID SECTION 90 814676R1 DECEMBER 1996 Q Reservoir Installation 5 Install grommet washer and screw cap to cylin der end cap Tighten screw securely 1 Connect trim motor wires to harness 2 Insert motor into reservoir Motor must be seated properly prior to end cap installation Screw Cap Washer Place drive shaft into oil pump Inst
32. Under Water Strike with Valves Open Shock Function with Valves Closed Shock Function Return Hydraulic System Troubleshooting Manual Tilt System Removal Manual Tilt System Disassembly Accumulator Removal Shock Rod Removal Shock Rod Disassembly Valve Block Removal Memory Piston Removal Valve Block Disassembly Actual O ring Sizes O ring Description and Sizes Manual Tilt System Cleaning and Inspection 5011 50 13 Manual Tilt System Reassembly 5G 27 Cam Shaft Reassembly 5G 27 Valve Body Check Reassembly 5G 27 Velocity Valve Reassembly 5G 27 Check Retainer Reassembly 5G 28 Valve Plug Reassembly 5G 28 Valve Block Installation 5G 28 Shock Rod Reassembly 5G 29 Shock Rod Installation and Fluid Filling Procedure 5G 30 Instructions for Making Retaining Tool 5G 31 Bleeding Manual Tilt System 5G 32 Manual Tilt System Installation 5G 34 Manual Release Valve Adjustment 5G 35 90 814676R1 DECEMBER 1996 c t Special Tools 1 Spanner Wrench P N 91 74951 2 Lock Ring Pliers P N 91 822778A3 LOCK RING PLIERS gt 90 814676R1 DECEMBER 1996 MID SECTION 5G
33. a Float Needle b Float c Baffle Plate FUEL SYSTEM AND CARBURETION 3 27 cM 9 Install pivot pin securing float to carburetor PRIMER FITTING DESIGNS 10 Seat splined portion of pivot pin into carburetor post DESIGN 1 DESIGN 2 a Pivot Pin b Float c Post 11 Install float bowl using new bowl gasket and se cure to carburetor body using primer fitting Torque fitting to 33 Ib in 3 7 N m See float bowl Primer Fitting Designs following 52027 Primer Fitting Bowl c Gasket 52018 Gasket 3 28 FUEL SYSTEM AND CARBURETION 90 814676R1 DECEMBER 1996 cM 13 Torque screws to 18 Ib in 2 0 N m 52012 a Screws 14 Connect throttle linkage to carburetor throttle shaft 52020 a Throttle Linkage b Throttle Shaft 90 814676R1 DECEMBER 1996 15 Connect fuel hose and primer hose to carburetor Secure fuel hose using sta strap 52012 a Fuel Hose b Primer Hose FUEL SYSTEM AND CARBURETION 3 29 Carburetor Installation 1 Install carburetors to powerhead using new gas kets Com 21 52021 2 Secure carburetors to engine using 4 nuts Torque nuts to 110 Ib in 12 4 N m 3 30 FUEL SYSTEM AND CARBURETION 3 Connectfuel line and primer line Secure fuel line using sta strap 52022 Nuts Torque to 110 Ib in 12 4 N m Fuel Line Primer Line Sta strap Reinstall oil tank Re
34. 5 Remove armature along with drive end cap from starter frame 6 If necessary remove parts from armature shaft by first removing locknut Then remove parts from shaft 11659 a Place Wrench on Hex Portion of Drive Assembly Removing Locknut Locknut Spacer Spring Drive Assembly Drive End Cap Armature Shaft Washer arts Removed from Armature Shaft ELECTRICAL AND IGNITION 2B 11 Starter Cleaning Inspection and Testing Cleaning and Inspection Clean all starter motor parts 2 Check pinion teeth for chips cracks or excessive wear 3 Replace the drive clutch spring and or collar if tension is not adequate or if wear is excessive 4 Check that the brush holder is not damaged or is not holding the brushes against the commutator 5 Replace brushes that are pitted or worn to less than 1 4 6 4mm in length 6 Replace a damaged or excessively worn bushing in the end cap 7 Check the armature conductor commutator bar junction for a firm connection A poor connection usually results in a burned commutator bar 8 Resurface and undercut a rough commutator as follows CAUTION Do not turn down the commutator excessively a Resurface the commutator and undercut the insulation between the commutator bars 1 32 0 8mm to the full width of the insula tion and so that the undercut is flat b Clean the commutator slots after undercut ting
35. 90 814676R1 DECEMBER 1996 Connect lanyard stop switch wiring harness as shown 3 4 Dy 54839 Black Yellow Lead from Mercury Stop Switch Black Yellow Lead from Outboard Wiring Harness Black Yellow Leads from Lanyard Stop Switch Black Lead to Outboard Ground Secure lanyard stop switch leads with sta strap 90 814676R1 DECEMBER 1996 Neutral Start Switch Wiring NOTE Electric Start Models 1 Remove ground lead f from solenoid terminal 54840 Connect ground lead f and ground lead d from Neutral Start Switch to switch box ground Connect remaining Neutral Start Switch wire h to solenoid terminal e 50221 Ground Lead Large Ring Terminal from Neutral Start Switch Solenoid terminal Ground Lead Removed from Solenoid Engine Ground Ground Lead Small Ring Terminal from Neutral Start Switch OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7B 9 3 Reinstall electrical box cover Battery Connections CAUTION g Failure to observe correct polarity when con necting battery cable to battery will result in Q damage to the charging system 1 Abattery with a minimum reserve capacity rating of 100 minutes minimum cold cranking
36. Clevis Attaching Installation P N 70599A4 NOTE This kit is used to attach Ride Guide cable to outboard steering arm ONLY when Transom Mounted Ride Guide Attaching Kit is being used If Ride Guide cable is installed thru outboard tilt tube then Steering Link Rod must be used Installation Instructions 1 Remove and discard existing steering bracket Two bolts and locking plate will be reused to install new steering bracket supplied in kit 7A 16 OUTBOARD MOTOR INSTALLATION ATTACHMENTS e 7 Useamarine type sealer on three 5 16 in x 3 1 4 in bolts Secure attaching kit to transom using transom backing plate 3 bolts with sealer and 3 locknuts installed as shown in Figure 2 Torque locknuts to 10 Ib ft 13 6 N m 50568 Locking retainer corner tabs MUST BE bent up and against flats on each bolt that secures steer ing bracket to outboard to prevent bolts from turning out 2 Install supplied steering bracket to outboard steering arm with two retained bolts and locking plate as shown below Torque bolts to 35 45 Ib ft 47 61 N m and bend tabs against flats of bolts 50579 a Locking Tabs Bent into Place IMPORTANT Lubricate all moving parts of clevis kit with Quicksilver 2 4 C Lubricant 90 814676R1 DECEMBER 1996 x f 3 Install clevis to steering cable as shown Clevis Steering Cable Bolt 3 8 24 x 1 3 8 Lubricate Unthreaded Area
37. Connect Voltmeter red lead to There is an open circuit between Point 6 Point 3 and positive battery ter Depress Up trim button minal Checkforloose or corroded con nections Check wires for open circuit Battery Voltage Indicated No Voltage Indicated e Pump motor wiring is defective Relay Switch is defective e Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 90 814676R1 DECEMBER 1996 MID SECTION 5C 19 2 Troubleshooting Down Up Circuits All Circuits Inoperative Blown Fuse Correct problem that caused fuse to blow Replace fuse No Voltage Indicated Check battery leads for poor connections or open circuits Check battery charge No Voltage Indicated Check that voltage is being supplied to control by performing the following checks DO NOT start engine Turn ignition switch to po sition Check for voltage at any instru ment using a Voltmeter No Voltage Indicated Red wire is open between Point 3 and red terminal on back of the ig nition switch Checkforloose or corroded con nections Check for open in wire 5C 20 MID SECTION Check in line fuse under cowl
38. Propeller Nut Gear Housing Removal To prevent outboard from accidentally starting remove and isolate spark plug leads from spark plugs prior to removing gear housing 1 Remove and isolate spark plug leads 2 Shift outboard into forward gear 3 Tilt outboard to full UP position 90 814676R1 DECEMBER 1996 4 Remove four lock nuts a securing gear housing to drive shaft housing one not shown 5 Remove gear housing AS 54750 Gear Housing Disassembly 1 Place gear housing in soft jawed vise 2 Remove shift shaft guide from shift shaft LOWER UNIT 6A 5 cM Remove centrifugal slinger a and three lock nuts and washers b 3 Remove seal a from drive shaft Water Pump Removal NOTE Outboard S N 0C245675 and above will not 1 seal drive shaft due to improved lower end cap design 51188 4 Remove seal and plate b from gear housing 2 Remove water pump body 3 Inspect body for cracks distortion or melting Re place if necessary a Water Pump Body b Screwdrivers c Shop Cloths 6A 6 LOWER UNIT 90 814676R1 DECEMBER 1996 p i 4 Remove nylon washer a and seal b 54755 5 Inspect water pump for grooves if grooved re place insert 54756
39. Q Periodic Inspection Conduct a periodic systematic inspection to uncover and correct a failure before it can cause inconve nience or mechanical damage Inspection interval is based on average operating conditions in utility ser vice Under severe conditions the inspection interval should be shortened Inspection includes 1 Clean entire unit thoroughly including all acces sible powerhead parts 2 Check entire unit for loose damaged or missing parts Tighten or replace as required 3 Lubricate gear housing as instructed previously Lubricate other points as indicated previously Lubricate starter motor shaft with light film of SAE 1OW motor oil Do not over lubricate 6 Service spark plugs Inspect spark plug leads and electrical leads for damage or deterioration as explained in Section 2 Electrical and Ignition section 7 Inspect fuel lines for damage or deterioration and service fuel filters as indicated in Section 3 Fuel System and Carburetion 8 Remove propeller and inspect Trim nicks and burrs with a file being careful notto remove more metal than absolutely necessary Inspect for cracks damage or bent condition If condition is doubtful refer to authorized Quicksilver Propeller Repair Station facilities Before reinstalling pro peller coat propeller shaft with Quicksilver Spe cial Lubricant 101 Anti Corrosion Grease or 2 4 C Marine Lubricant 9 Inspectthe outboard surface finish for dama
40. Suction Seat Assembly Manifold Removal 1 Remove two 2 screws to remove manifold from cylinder 51146 a Screw 2 5E 30 MID SECTION cM 2 Remove tilt relief components 8 a b 9 A d 51008 a Spring b Poppet Spool Housing d Trim Limit Spool Shock Rod Removal 1 Unscrew end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs 90 814676R1 DECEMBER 1996 Q Shock Rod Disassembly NOTE The only serviceable items on the shock rod assembly are the O rings and wiper ring If shock rod requires any other repair replace shock rod assem bly e b 0 b O ring c Wiper Ring 1 Place shock rod assembly on clean work surface 2 Remove three 3 screws and remove plate from shock rod piston 51143 a Screw 3 b Plate Shock Rod Piston 90 814676R1 DECEMBER 1996 3 Remove check ball components from shock rod piston 4 Remove o ring from shock rod piston P 51147 Spring 5 Seat 5 Ball 5 O ring MID SECTION 5E 31 A CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to shock piston 5 Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 6 Loosen shock rod piston using spa
41. Water testing Checking for Cavitation Continued 2 Rough Water Plate Using this type of plate may be helpful in reducing cavitation when running in windy rough water conditions where air is sucked in the water intake when jumping waves Install a 1 32 in metal plate that extends from the hull bot tom to the top of the water intake housing This plate tends to reduce air intake as well as reduce spray b Rough Water Plate Shift Cable Installation The shift cable must be adjusted to lock the re verse gate against unexpected engagement caused by water pressure hitting the gate while operating the boat in forward Activation of the re verse gate will cause sudden unexpected stop ping of the boat Sudden stopping may cause oc cupants to be thrown within the boat or even out of the boat This action may result in serious inju ry or death 1 Attach shift cable to the shift cam with flat washer and locknut as shown Tighten locknut against the flat washer then back off the locknut 1 4 turn 2 Placeremote control handle into full forward posi tion 3 Adjust the brass barrel on the shift cable so that roller is at the full end of travel bottom in the shift cam when the remote control is in full forward 90 814676R1 DECEMBER 1996 4 Attach the brass barrel to the bracket with bolt and locknut Tighten the bolt until it seats against the barrel then back off the bolt 1 4 turn Hold bolt from turning a
42. c With crankshaft against lower end cap feeler gauge and check measurement be tween inner race of upper ball bearing and thrust face of crankshaft Correct end play should be between 008 to 012 0 203mm to 0 305mm ut auff a Top End Cap Ball Bearing b Top Crankshaft Throw d If necessary add or remove shim s to attain correct end play Keep shim s thickness approximately the same within 005 0 127mm between upper and lower end caps to assure that crank pin throws are cen tered over cylinders 11 Loosen end cap bolts several turns and slide end caps away from cylinder block to allow crankcase cover to be installed 12 Thoroughly clean machined mating surface of crankcase cover and cylinder block with solvent to remove all oil CAUTION Before applying Loctite Master gt Gasket 92 12564 1 to cylinder block make sure that mating surfaces of crankcase cover and cylinder block are clean and free of oil Locquic Primer can be used to clean these surface Loctite must be applied in a continuous bead along the inside of mounting bolt holes If a void should occur when applying a bead of Loctite either remove the entire bead with a rag or apply with additional bead parallel to the void and overlapping the pre viously applied bead Assemble crankcase cover to cylinder block without lateral movement 90 814676R1 DECEMBER 1996 n 13 Apply a continuous bead of Locti
43. 400 2 Crank engine and observe meter reading Voltage at 300 RPM cranking Voltage at 1000 4000 RPM Running 190 Volts 275 to 320 Volts TEST RESULTS e Voltage output is high The adapter module is de fective Replace adapter module Good voltage output e No voltage output or low voltage output Go to STEP 5 Stator Adapter Module and Switch Box Test 90 814676R1 DECEMBER 1996 ax i Ignition Troubleshooting Engines With Red Stator STEP 5 Stator Adapter Module and Switch Box Test Elimination Test y 1442444 BLU Set multipurpose switch position to 400 DVA Disconnect only the BLU wire from the switch box Connect test leads between BLU wire and engine ground Crank engine and observe meter reading Reconnect BLU wire Disconnect only the BLU WHT wire from the switch box Connect test leads between BLU WHT wire and engine ground Crank engine and observe meter reading Voltage at 300 RPM cranking 190 to 260 Volts TEST RESULTS 90 814676R1 If voltage output is good on both wires the switch box is defective Voltage output is low on either wire continue with test DECEMBER 1996 Between GRN WHT and WHT GRN Stator leads Disconnect the GRN WHT and WHT GRN sta
44. 5 If necessary clean crankshaft surfaces with 320 cloth 54709 a 320 Cloth 90 814676R1 DECEMBER 1996 c DO NOT spin dry crankshaft ball bearings with compressed air 6 Thoroughly clean with solvent and dry crank shaft ball bearings Recheck surfaces of crank shaft Replace crankshaft if surfaces cannot be properly cleaned up If crankshaft will be re used lubricate surfaces of crankshaft with light oil to prevent rust Ball Bearing 1 Clean ball bearings with solvent and dry with compressed air 2 Attempt to work inner bearing race in and out There should not be excessive play 3 Lubricate ball bearing with light oil Rotate outer bearing race Bearing should have smooth action and no rust stains If ball bearing sounds or feels rough or has catches remove and discard bearing Refer to Powerhead Disassembly preceding 90 814676R1 DECEMBER 1996 Powerhead Reassembly General Before proceeding with powerhead reassembly be sure that all parts to be re used have been carefully cleaned and thoroughly inspected as outlined in Cleaning and Inspection preceding Parts which have not been properly cleaned or which are ques tionable can severely damage an otherwise per fectly good powerhead within the first few minutes of operation All new powerhead gaskets MUST BE installed during reassembly During reassembly lubricate parts with Quicksilver Formula 50 D 2 Cycle Outboard
45. 51144 a Manual Tilt System 5F 22 MID SECTION Manual Tilt System Disassembly NOTE Accumulator contains a high pressure nitro gen charge and is NOT SERVICEABLE Replace if necessary This tilt system is pressurized Remove accumu lator only when shock rod is in full up position Accumulator Removal 1 Place manual tilt system in soft jawed vise 2 Position shock rod to full up position 3 Remove accumulator 51143 a Shock Rod b Accumulator 90 814676R1 DECEMBER 1996 i 4 f plunger can be compressed into accumulator Shock Rod Removal by hand accumulator is defective Replace accu mulator 1 Remove cylinder end cap assembly using span ner wrench 1 4 in x 5 16 in long pegs 51145 51143 a Plunger 5 Remove O ring 51143 51145 90 814676R1 DECEMBER 1996 MID SECTION 5F 23 3 Remove memory piston from cylinder using lock ring pliers Craftsman P N 4735 or suitable tool 51144 51144 a O ring b Memory Piston 5 Remove tilt system from vise and empty fluid into appropriate container 5F 24 MID SECTION PAN Shock Rod Disassembly 1 Place shock rod assembly on clean work surface 2 Remove plate and O ring 3 Remove check ball components from shock rod piston Screw 3 Plate O ring Shock Rod Piston A CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid dama
46. BLK Black BLU Blue BRN Brown N GRY Gray x GRN Green Coy N ORN Orange aen PNK Pink om My N PUR Purple Wy IN RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark a Ignition Choke Switch b Emergency Stop Switch Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn g Trim Tilt Switch 23891 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 13 2 Commander 2000 Side Mount Remote Control Electric Start with Warning Horn Wiring Diagram BLK 4 TAN BLU 3 YEL BLK 6 PUR 2 TAN BLU C GRY B BLK 0 PUR A YEL RED 7 BLK YEL 1 RED 8 BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark a Ignition Choke Switch b Emergency Stop Switch c Neutral Start Switch d Tachometer Accessories Harness Connector e Wiring Harness Connector f Warning Horn 23892 2D 14 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 aX CE Commander 2000 Side Mount Remote Control Manual Wiring Diagram ION BLK Black Pd N BLU Blue ae BRN Brown P d y GRY Gray d 2 GRN Green P d ORN Orange N X PUR Purple d RED Red TAN Tan P dis d WHT White S d YEL Yellow gt x
47. CYLINDER BLOCK COVER BOLTS 1 i EP l ZA il WI 5 fi NA 529 POWERHEAD DRIVESHAFT HOUSING 12 5 Ib ft 17 0 Sequence and Torque Speci fications 90 814676R1 DECEMBER 1996 4 10 POWERHEAD Powerhead Removal from 5 Remove shift and throttle cables from engine Driveshaft Housing Electric Start Model 1 Disconnect powerhead battery cables from bat tery Remove top cowling Remove Spark Plug leads from spark plugs Disconnect powerhead and remote control elec trical harness connector Disconnect remote control trim control leads BLUE WHITE and GREEN WHITE if applicable 50564C a Throttle Cable b Shift Cable 6 Remove POSITIVE LEAD from starter motor 7 Remove four bolts securing starter motor and re move retaining clamps and starter motor from powerhead a Harness Connector b Trim Control Leads 54652 a Positive Lead b Starter Motor Bolts d Retaining Clamps 90 814676R1 DECEMBER 1996 POWERHEAD 4 11 8 Disconnect two blue low oil level leads at their bullet connectors 9 Disconnect blue white and green white power trim switch leads at their bullet connectors Blue Leads Blue White Lead Green White Lead Trim Switch 10 Re
48. Check Ball 2 Remove screws and manifold from cylinder a Drive Shaft b Oil Pump 51007 a Trim Cylinder b Manifold Screw 90 814676R1 DECEMBER 1996 MID SECTION 5C 27 IMPORTANT Removal of O ring from man ifold will result in damage to O ring O ring MUST be replaced after removal 3 Remove check valve components from manifold NON 51736 Manifold Spring Check Valve Check Valve Seat O ring Spring Sleeve Spool rO A200 5C 28 MID SECTION 4 Remove O rings from cylinder 51008 a O rings Cleaning and Inspection of Trim Rod Components IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction A CAUTION Do not remove check valve components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam age 51199 Inspect check valve for debris clean debris form check valve if found If debris cannot be cleaned from check valve replace trim rod piston as an assembly Clean trim rod and components with parts cleaner and dry with compressed air It is recommended that all O rings in trim system be replaced Inspect trim rod If scraper located in cap has failed to keep rod clean replace scraper Lubricate all O rings using Quicksilver Power Trim and Steering
49. Checking Forward Gear Backlash NOTE Read entire procedure before attempting any change in shim thickness 1 Obtain correct pinion gear depth Refer to Checking Pinion Gear Depth preceding 2 Install components as shown pe a Propeller Shaft b Puller Jaws 91 46086 1 Puller Bolt 91 85716 Torque to 45 Ib in 5 1 N m 3 Rotate drive shaft 5 to 10 revolutions This will properly seat forward gear tapered roller bearing gt Install components as shown Position dial indicator on line 4 of backlash indica tor tool m n A 54811 a Dial Indicator Adaptor Kit 91 83155 b Dial Indicator 91 58222A1 c Backlash Indicator Tool 91 78473 90 814676R1 DECEMBER 1996 6 Lightly turn drive shaft back and forth no move ment should be noticed at propeller shaft 7 Dial indicator registers amount of backlash Backlash should be between 007 in and 010 in 0 178mm to 0 254mm 8 If backlash is less than minimum specification remove shim s from front of forward gear bear ing race to obtain correct backlash When rein stalling pinion nut apply Loctite 271 on threads of nut 9 If backlash is more than maximum specification add shim s in front of forward gear bearing race to obtain correct backlash When reinstalling pin ion nut
50. Loctite Grade A 271 P N 92 32609 1 50508 LOWER UNIT 6A 3 Draining and Inspecting Gear Housing Lubricant If gear housing is installed on outboard discon nect and isolate spark plug leads to avoid acci dental starting when working near propeller 1 With gear housing in normal running position place a clean pan under housing and remove vent screw and gasket a and fill drain screw and gasket b 26473 Trim Tab Propeller Removal 1 Place reference mark on trim tab a and anti ventilation plate b to allow trim tab to be rein stalled at the same angle 2 Remove nylon plug from drive shaft housing and remove bolt securing trim tab to gear housing 6A 4 LOWER UNIT If gear housing is not removed before attempting to remove or install the propeller remove and isolate spark plug leads from spark plugs to pre vent outboard from starting accidentally 3 Bend tabs a away from propeller nut b 90 814676R1 DECEMBER 1996 4 Place block of wood between gear case and propeller to hold propeller and remove propeller nut 5 Remove propeller and components from shaft Flo Torq Drive Hub Propellers a Forward Thrust Hub b Propeller Nut Retainer Propeller Nut Flo Torg Il Drive Hub Propellers ed p Forward Thrust Hub Replaceable Drive Sleeve Rear Thrust Hub Propeller Nut Retainer
51. Mandrel Driver Rod Mandrel Mandrel 91 91947 91 34568A1 91 46086A1 91 27780 91 37241 91 24273 91 23033 91 89670 91 58222A1 91 83155 91 78473 91 85716 91 37312 91 37311 91 38628 91 36569 91 37323 91 31361 91 86290 From Bearing Puller amp Installation Kit P N 91 31229A5 90 814676R1 DECEMBER 1996 Quicksilver Lubricants and Service Aids Description Special Lubricant 101 92 13872A1 Loctite Grade A 271 92 32609 1 Needle Bearing Assembly 92 42649A 1 Lubricant 2 4 C Marine Lubricant See Quicksilver Accessories Guide for part num bers LOWER UNIT 6 1 Gear Housing Assembly Drive Shaft Components Gear Housing Lubrication Sealant Application Speedometer Hose Dowel Pin 2 Points Stud 3 Stud 2 E A C 2 4 Marine Lubricant Needle Bearing P N 92 90018A12 Water Inlet 2 Special Lubricant 101 P N 92 13872A1 Locknut E E Needle Bearing Assembly Lubricant 12 Pinion Gear P N 92 42649 1 13 Pinion Nut 14 Gasket H D Quicksilver Gear Lubricant 15 O ring P N 92 13783A24 16 Water Pump Base 17 Seal B Loctite Grade 271 P N 92 32609 1 18 Oil Seal 19 Dowel Pin 2 20 Gasket 21 Face Plate 22 Gasket 23 Impeller 24 Drive Key 25 Insert 26 Water Pump Body 27 Seal 28 Washer Nylon 29 Washer 30 Nut 31 Centrifugal Slinger Rubber 32 Seal Rubber 3
52. NOTE It will be necessary to lift control cable rubber grommet out of opening in bottom cowl so that con trol cables can be routed thru grommet and into bot tom cowl 90 814676R1 DECEMBER 1996 5 SAG x 50566 Control Cable Rubber Grommet Shift Cable Opening Throttle Cable Opening Remote Control Wiring Harness Key Switch Wiring Har ness Opening Shift Cable Installation Adjustment to Engine NOTE Attach shift cable to engine first Shift cable is the first cable to move when remote control handle is advanced from neutral position toward in gear position If remote control has a neutral lock release secure the release in the depressed position using a piece of tape Now you can locate the true neutral detent NOTE Rotate remote control handle back and forth You will feel three detent positions center detent is neutral 1 Position remote control handle into neutral det ent 2 Manually shift outboard into neutral propeller will rotate freely OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 19 Route shift cable a thru control cable grommet b Adjust barrel c of shift cable to attain the same distance between barrel and hole in end of shift cable guide as exists between barrel receptacle d and peg e of shift actuator with a slight pre load adjustment toward reverse Lift barrel receptacle out of recess f in bottom cowl insert shift cable barrel into lower hole o
53. REX RE RR RYE 5C 3 Power Trim Flow Diagrams Design Il 5C 4 DeSiOn 1 5 5 Design 5 6 Design m percer rr 5C 7 Design IL cine PER Ed 5C 8 Design 5 9 DERE IMMER 5C 10 Troubleshooting 5C 11 Determining if Problem is Electrical or Hydl auliG Ed ER 5C 11 Trouble Chart 5C 11 Hydraulic System Troubleshooting 5C 12 Preliminary Checks 5C 12 Leak Down Check Pump and Manifold Assembly 5C 12 Leak Down Check Pilot Valve Assembly 5C 13 Leak Down Check Manual Release NENG ito 5C 13 Leakage Past Ball and Seat Piston Assembly Dada ets 5C 13 Troubleshooting Flow Diagram 5C 14 Troubleshooting Flow Diagram 5C 15 Electrical System Troubleshooting 5C 16 COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5C 16 Power Trim System Wiring Diagram 5C 17 Troubleshooting the Down Circuit When Up Circuit is 5C 18 Troubleshooting the Up Circuit When Down Circuit Is OK 5C 19 Troubleshooting the Down and Up Circuits All Circuits Inoperative
54. Temperature Gauge Sender Warning Module 10 Overheat Switch Enrichment Valve 12 20 Ampere Fuse 13 Switch Box 14 Ignition Coil 1 Cylinder 90 814676R1 DECEMBER 1996 YEL CP YEL RED YEL BLK YEL BLK 15 Ignition Coil 2 Cylinder 16 Ignition Coil 3 Cylinder 17 Ignition Coil 4 Cylinder 18 Low Oil Sensor 19 RPM Limiter 20 To Female Connector on Remote Control Harness Plug 21 To Bottom Cowl RED ie P P 53472 ELECTRICAL AND IGNITION 2D 1 f Wiring Diagram Model 30 Jet with 16 Amp Red Stator BLK BLU BRN GRY GRN ORN PNK PUR RED Tan WHT YEL LIT DRK 7 Brown Gray Green Orange Pink Purple Red Tan White Yellow Light Dark CD VEL YEL Rr C p VEL RE y RED YEL 2 17 BLK 54944 16 Ampere Stator Ground Connection Switch Box Stator Adaptor Voltage Regulator 2D 2 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 c Wiring Diagram Model 30 Jet Tiller Handle with 16 Amp Black Stator BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN WHT WHITE YEL lt YELLOW LIT BLU LIGHT BLUE Stator Trigger Starter Starter Solenoid Battery Engine Harness Neutral Start Switch Temperature Gauge Sender RPMLimiter
55. scribed preceding the gear housing must be re moved and the cause corrected 54818 6A 28 LOWER UNIT 90 814676R1 DECEMBER 1996 LOWER UNIT JET DRIVE Table of Contents Page NOTES 23294080 RR 6B 1 Jet Pump Assembly 6B 2 Selecting A Boat Best Suited For Jet Power 6B 4 Engine Horsepower Selection 6B 4 Transom Height of the Boat 6B 5 Locate Centerline of The Outboard 6B 5 Outboard Mounting Height 6B 5 Water Testing 6B 6 Checking for Cavitation 6B 6 Shift Cable Installation 6B 7 Lubricating The Drive Shaft Bearing 6B 8 Impeller Removal and Installation 6B 8 Steering Pull Adjustment 6B 10 Impeller Clearance Adjustment 6B 10 Page Worn Dull Impeller 6B 10 Liner Replacement 6B 11 Jet Drive Removal and Installation 6B 11 Water Pump Removal and Installation 6B 12 Bearing Carrier Removal and Installation 6B 12 Bearing Carrier Disassembly 6B 13 Bearing Carrier Reassembly 6B 13 Installing Lower Seals 6B 13 Installing Upper Seals 6B 14 Installing Drive Shaft Ball Bearing 6B 14 Installing Drive Shaft 6B 14 Installing Upper Seal Housing 6
56. tor leads from the adapter module GRN WHT WHT GRN CI BLU WHT Measure resistance between the GRN WHT and WHT GRN stator leads Test Leads To Meter Reading 660 710 TEST RESULTS If the resistance is OK 660 to 710 ohms the adapter module is defective Replace adapter module If the resistance is incorrect the stator is defec tive Replace stator ELECTRICAL AND IGNITION 2A 9 Ignition Component Testing Trigger Test BRN S PUR BLK O WHT 1 Disconnect all trigger leads form switch box 2 Use a VOA meter and perform the following checks Meter Reading Test Leads Between BRN lead and BLK R x 100 700 1000 lead Ohms Between WHT lead and R x 100 700 1000 PUR trigger lead Ohms NOTE Above resistance readings are for a cold en gine room temperature Resistance will increase if engine is warm 3 If meter readings not as specified replace trigger 2 10 ELECTRICAL AND IGNITION Ignition Coil Test 1 Disconnect wires from coil terminals Pull spark plug lead out of coil tower Use a VOA meter and perform the following checks Meter Reading Between and Coil Rx 1 02 04 Test Leads To Terminals Ohms Between Coil Tower and R x 100 800 1100 Coil Terminal Ohms The primary DC resistance of these coils generally is less than one 1 OHM
57. 7 Remove oil outlet hose from oil reservoir and re 8 move reservoir from outboard J gt ba a Oil reservoir 54868 b Support Pocket a Oil Outlet Hose 4 Reinstall flywheel cover while aligning oil fill cap 3 and sealing O ring oil reservoir Torque fly d _ 522 wheel cover bolts to 100 Ib in 11 3 5 Remove oil fill cap and fill reservoir with QUICK SILVER 2 CYCLE OUTBOARD OIL or an ac ceptable oil rated BIA TC W or TC WII Check oil outlet hose on reservoir for leakage 6 Reinstall reservoir fill cap Reinstall top cowling Reconnect engine battery cables to battery 90 814676R1 DECEMBER 1996 OIL INJECTION SYSTEM 8 11
58. 90 814676R1 DECEMBER 1996 MID SECTION 5C 15 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram BLK 4 YEL BLK 6 YEL RED 7 RED 18 Black Blue BRN Brown GRY Gray GRN Green PUR Purple RED Red TAN Tan WHT White YEL Yellow Warning Horn Trim Tilt Switch BN d Ignition Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer Accessories Harness Connector 23891 Wiring Harness Connector TAN BLU GRY PUR 12 BLK D PUR BLK YEL 11 YEL RED PUR PUR v ap v ar 2 5C 16 MID SECTION 90 814676R1 DECEMBER 1996 96704 ALOWSY LNNOW 395 2 aas Cu 1 Ad3lliva 1HAV f8 OL a Y ON o Coes m ee dION310S H31HVIS HOLOW i rll H3MOd I 2 co 1 TRIM MODULE Power Trim System Wiring Diagram c 56 2 559 mmaoomcsz e o v25zarc a MID SECTION 56 17 DECEMBER 1996 90 814676R1 c Troubleshooting the Down Circuit When Up Circuit is OK Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Battery Volt
59. 91 99379 to No 1 TOP spark plug lead IMPORTANT If carburetors were previously re moved it is recommended that they be synchro nized prior to making any timing adjustments Refer to SECTION 3 for proper synchronization procedures THROTTLE PRIMARY PICK UP ADJUSTMENT 1 Engage electric starter and advance throttle spark arm until specified primary pickup timing mark aligns with V notch in timing pointer win dow of flywheel cover 54658 a V Notch b Window 2 Hold throttle spark arm steady and turn IDLE RPM SCREW until it just touches its stop WHile holding throttle spark arm against IDLE RPM SCREW STOP verify specified primary pick up timing mark is still aligned with V notch If timing mark has changed adjust IDLE RPM SCREW to realign timing mark ELECTRICAL AND IGNITION 2C 1 NOTE By holding the throttle spark arm against the IDLE RPM SCREW 5 a constant timing refer ence point is provided while adjusting throttle actua tor plate IMPORTANT After all timing adjustments have been made the IDLE RPM SCREW will have to be readjusted to provide the proper idling RPM for the outboard while it is running a Idle RPM Screw 3 Loosen throttle actuator plate retaining screws LER S c 2 FAAET eh zu 5 pue A 3 54660 Throttle Actuator Plate Retaining Screws Secondary Throt
60. DOT 178 m Shock Piston 55 068 2021 63096 mm 021m 5394 mm 75 Piston Bok 05 6 717 mm G0726 mm 007m 78m Motor Seal 8 2 Check Plug 0 489 12 42 mm 0 629 in 15 97 mm 0 07 in 1 78 mm 9 3 Poppet Assy 1 Poppet Assy 007 178 0 239 in 6 07 mm 0 07 in 1 78 mm 0 114 in 2 90 mm 0 254 in 6 451 mm 0 07 in 1 78 mm 0 176 in 4 47 mm 0 07 in 1 78 mm 7 0 239 in 6 07 mm 0 379 in 9 626 mm 0 07 in 1 78 mm 0 YH a bad 239 in 6 07 0 379 9 626 0 07 1 78 mm 19 3 Spool Housing 0 301 in 7 645 mm 0 441 in 11 20 mm 10 07 1 78 Trim Limit Spool 0 114 in 2 895 mm 0 254 in 6 451 mm 0 07 1 78 mm 2 0 208 5 283 mm 0 348 in 8 839 mm 0 07 in 1 78 mm Memory Piston 1 6 in 40 64 mm 2 02 in 53 086 mm 0 21 in 5 334 mm a _ ma 90 814676R1 DECEMBER 1996 MID SECTION 5E 37 Power Reassembly IMPORTANT Lubricate all o rings with Quicksil ver Power Trim Fluid 92 90100A12 If not avail able use automotive ATF automatic transmis sion fluid Shock Rod Reassembly 1 Install lubricated o rings to end cap 2 Install rod wiper 51145 a Rod Wiper b Inner O ring Outer O ring 3 Install lubricated o rings to shock piston 51199
61. Fresh Water Salt Water DELE Type of Lubricant Frequency Frequency Throttle S hift Linkage Pivot Points Upper Shift Shaft Quicksilver 3 Tilt Lock Lever 24 C Marine 4 SwielPin Pin Lubricant Steering Cable Tilt Tube Steering Link SAE 30W Every Every Rod Pivot Points Motor Oil 60 Days 30 Days Quicksilver Special Lubricant 101 Propeller Shaft Anti Corrosion Grease 2 4 C Marine Lubricant Starter Motor SAE 10W Once in Every Pinion Gear Motor Oil Season 60 Days Once in Every Season 60 Days Quicksilver Gear Housing Special Lubricant After first 20 Bearing Carrier 101 hours then and Cover Nut 2 4 C Marine once in season Lubricant Check and fill Check and fill after first 10 after first 10 days then days then every 30 days every 30 days Drain and refill Drain and refill Gear Housing 2 after 15125 after 15125 hours then hours then after every 100 after every 100 hours oronce hours or once ayearbefore a year before storing storing Engine Quicksilver 2 Upper Shift Shaft Lubrication Crankshaft 2 4 Once in Once in Splines to Drive Marine Season Season Shaft Splines Lubricant Refer to lubrication instructions outlined in Salt Water Corrosion Gear Housing Bearing Carrier and Cover Nut of this section see Table of Contents Refer to Gear Housing Lu
62. Gear Housing Reassembly Drive Shaft Needle Bearing Installation 1 Drive needle bearing into housing until approxi mately even with drive shaft cavity a Mandrel 91 37312 b Needle Bearing Numbered Side Up 6A 16 LOWER UNIT c iti Shift Shaft Bushing Reassembly and Installation 1 Press new oil seal a into bushing with lip of seal away from threaded end of bushing Install new O ring b 2 Lubricate lip of seal and O ring with Quicksilver 2 4 C Marine Lubricant M 3 Assemble shift shaft 4 Apply Quicksilver Special Lubricant 101 to threads of shift shaft bushing 54790 a Shift Shaft b E Clip c Bushing d Rubber Washer 90 814676R1 DECEMBER 1996 5 Place shift cam Number Side Up into gear housing and install shift shaft assembly Torque bushing to 17 lb in 23 54777 a Shift Shaft Bushing Tool 91 23033 b Shift Shaft c Shift Cam Numbered Side Up Lubrication Sleeve Installation 1 Install lubrication sleeve into gear housing NOTE Lip of lubrication sleeve must be below drive shaft bearing race shim shoulder If lip is above shoulder the drive shaft needle bearing may not be seated deep enough 90 814676R1 DECEMBER 1996 M V q q Fok TY 1 Press needle bearing numbered side toward
63. Locknut Clevis to Steering Cable Torque to 120 Ib 14 N m CAUTION Clevis must be connected to the middle hole in the steering bracket below to ensure proper en gine clearances Failure to use middle hole could cause steering system to bind 0 9 a Proper Hole to be Used 90 814676R1 DECEMBER 1996 4 Install clevis to middle hole in steering bracket as shown 50137 a Clevis Bolt 3 8 in 24 x 1 7 8 in Torque to 240 Ib in 27 N m Lubricate Unthreaded Area Washers 1 16 in Thick Spacer Small Lubricate Spacer Spacer Large Locknut Clevis to Engine Steering Bracket Torque to 240 Ib in 27 N m g Steering Bracket o Maintenance Instructions Lubrication and maintenance inspection is owner s responsibility and must be performed at intervals as specified following Normal Service Every 50 hours of operation or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation in salt water area is considered Severe Service 1 Carefully check steering components for wear If worn take your local Authorized Dealer 2 Check steering system fasteners to be sure that they are torqued to correct specifications 3 Lubricate clevis pivot points with a drop of light oil 4 Inspection and lubrication of steering system should be performed once each year by your Au thoriz
64. Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all o rings be replaced when servicing tilt system 5E 2 MID SECTION 90 814676R1 DECEMBER 1996 POWER TRIM COMPONENTS TORQUE DESCRIPTION Ib in Ib ft POWER TRIM PUMP SHOCK ROD KIT MEMORY PISTON ASSEMBLY O RING REBUILD KIT O RING CYLINDER ASSEMBLY TRIM LIMIT VALVE KIT PUMP ASSEMBLY MOTOR KIT RESERVOIR PLUG Drive Tight MANUAL RELEASE ASSEMBLY Drive Tight MANIFOLD KIT SCREW KIT MOTOR DRIVE SHAFT FILTER KIT P O CHECK ASSEMBLY KIT CABLE O RING KIT COMPLETE TRIM GROOVE PIN ANCHOR PIN PIN BRACKET HARNESS Trim SCREW M6 x 25 RELAY BRACKET GROMMET BUSHING A Torque cylinder cap to 45 Ib ft 61 B Torque screws to 80 Ib in 9 0 C Torque screws to 70 Ib 7 9 D Torque plugs to 120 Ib 13 5 E Torque screws to 100 Ib in 11 N m F Torque shock piston to 90 Ib ft 122 N m By nm PV DPD N N 90 814676R1 DECEMBER 1996 MID SECTION 5E 3 Theory Of Operation The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The remote control or trim
65. NOT burr or round machined edges Clean pol ish piston skirt with crocus cloth 5 After thoroughly cleaning pistons check each piston size and roundness using a micrometer Piston must be measured as described follow ing 90 814676R1 DECEMBER 1996 Measuring Piston Roundness Piston has a tapered cam profile shape and is not a true diameter Using a micrometer measure dimension A at loca tion shown Dimension should be as indicated in chart following 13 Dimensions at Right Angle 90 to Piston Pin b1 19mm Piston Cyl Block Measurements Finish Dimension Hone Standard 2 558 2 565 Piston 64 97mm 65 15mm 015 Oversize 2 573 2 580 Piston 65 35mm 65 53mm 030 Oversize 2 588 2 595 Piston 65 74mm 65 91mm Reed Blocks IMPORTANT DO NOT remove reeds from reed block unless replacement is necessary DO NOT turn used reeds over for re use 1 Thoroughly clean reeds and reed block 2 Placereed block halves together and secure with screws and nuts 3 Checkfor wear indentation on face of each reed block If reeds have made indentations replace block Check for chipped or broken reeds 5 Check reeds to be sure that they are not pre loaded adhere tightly to reed block and that they are not standing open an excessive amount greater than 007 0 78mm 90 814676R1 DECEMBER 1996 54706 a Feeler Gauge b Reed 6 Replace reeds as nec
66. Outboard will not hold trim position Refer to Electrical System when in reverse Troubleshooting 90 814676R1 DECEMBER 1996 MID SECTION 5B 11 Hydraulic System Troubleshooting Support outboard with tilt lock lever when servicing power trim system IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reas sembly IMPORTANT Power trim system is pressurized Outboard must be in the full UP position cylin der fully extended prior to fill screw or manual release valve removal Refer to instructions following if disassembly is re quired Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks IMPORTANT Operate Power Trim system after each check to see if problem has been corrected If problem has not been corrected proceed to next check 1 Check that manual release valve is tightened to full right clockwise position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Fill and Purge the Power Trim System 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls to trim in po
67. Remove reed block from crankshaft Reassemble each reed block as it is removed to assure correct rematch of each assembly Inspect reed blocks as outlined in Cleaning and Inspection following If inspection indicates that replacement of a part is necessary remove part from reed block Remove two bolts which secure both halves of the center main bearing support together Re move center main bearing support from crank shaft ao se Ep 3 a Center Main Bearing Support b Bolts Locating Pin 4 24 POWERHEAD 90 814676R1 DECEMBER 1996 Q Cleaning and Inspection Cylinder Block and Crankcase Cover IMPORTANT Crankcase cover and cylinder block are a matched line bored assembly and never should be mismatched by using a different crankcase cover or cylinder block CAUTION While honing and cleaning procedures are being performed on cylinder block all bleed system components hoses fittings and check valve MUST BE REMOVED from cylinder block to pre vent damage from abrasive materials Cylinder Bore Cleaning and Inspection 1 Inspect cylinder bores for scoring scuffing or a transfer of aluminum from piston to cylinder wall Scoring or scuffing if NOT TOO SEVERE can normally be removed by honing If a transfer of aluminum has occurred an acidic solution such as Tidy Bow
68. Starter Rope Handle Retainer Knot a Interlock Actuator b Interlock Cam Interlock Cable 7C 8 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 90 814676R1 DECEMBER 1996 cM OIL INJECTION SYSTEM Table of Contents Page Operation of the Oil Injection System 8 1 Oil Injection Components 8 1 Oil Injection Flow 8 2 Pump Drive Assembly 8 3 Pump Drive System 8 3 Oil Pump to Powerhead Assembly 8 4 Torque Specifications 8 4 Quicksilver Lubrication Sealant Application 8 4 Set Up Instructions for Oil Injection System 8 5 Filling the Oil Injection System with Oil 8 5 Bleeding Air from Oil Injection System 8 5 Bleeding Air from Oil Pump Inlet Hose 8 5 Bleeding Air from Oil Pump Outlet Hose 8 5 Operation of the Oil Injection System 8 6 Check Operation of the Oil Injection System Engine Running 8 6 Required Side Mount Remote Control or Ignition Key Switch Assembly to be Used with Engines Equipped with Oil Injection 8 6 Boats Equipped with a Side Mount Remote 8 6 Boats Equipped with Panel or Console Mount Remote Control 8 6 Oil Injection System Troubleshooting Gha enced
69. Steering Cable Routed for Port Entry into Outboard Tilt Tube TILT TUBE REVERSAL CAUTION Outboard tilt tube MUST BE removed and rein stalled in the opposite direction turned end for end so that when reassembled longer threaded end of tilt tube extends out port side of outboard approximately 3 4 in 19mm Failure to reposi tion outboard tilt tube as described could inter fere with steering system operation Remove outboard tilt tube and reinstall in opposite direction turn end for end so that when reas sembled longer threaded end a of tilt tube extends out port side of outboard approximately 3 4 in 19mm Refer to Section Midsection 50579 Refer to Quicksilver Accessories Guide to deter mine correct length of steering cable and remote con trol cables IMPORTANT Steering cable and remote control cables must be the correct length sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables Install steering mount and steering wheel in accor dance with installation instructions that accompany each 7A 6 OUTBOARD MOTOR INSTALLATION ATTACHMENTS Installing Ride Guide Cable to Outboard Tilt Tube IMPORTANT Before installing steering cable into tilt tube lubricate entire cable end with Quicksilver 2 4 C Marine Lubricant NOTE Ride Guide Steering Cable is lubricated at the
70. Steering Fluid or ATF Type FA or Dexron Il 3 Install lubricated O ring to memory piston and place into cylinder Push piston down to level of oil Install lubricated O ring to trim rod piston Install check valve components into their respec tive seats Secure components in place using plate and screws Torque screws to 35 Ib in 4 0 N m a O ring b Memory Piston IMPORTANT Memory piston must not come in contact with trim rod end cap during end cap trim rod installation 51147 Screw 3 Plate O ring Ball 5 Seat Spring 5 Spring 5 90 814676R1 DECEMBER 1996 MID SECTION 5C 35 4 Install trim rod into cylinder 51196 IMPORTANT Memory piston must not come in contact with trim rod end cap during end cap trim rod installation 5 Tighten end cap assembly to cylinder securely using trim cylinder spanner wrench 1 4 in x 5 16 in long pegs 51145 6 Tighten manual release valve snuggly following end cap installation 5C 36 MID SECTION Bleeding Power Trim Unit IMPORTANT Manual release valve must be in the closed position during power trim bleeding and operation 1 Secure power trim unit in soft jawed vise 2 Remove fill screw Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF Type FA or Dexron II up to threads of reservoir Install cap m M i D 50241 3 Using a 12 volt power supply c
71. Throttle Secondary Pick Up Adjustment Outboard Not Running 2C 3 Full Throttle Stop Screw Adjustment Outboard Not Running 2C 4 Carburetor Adjustments 2C 5 Idle Mixture Screw Adjustment 2C 5 Idle RPM Adjustment 2C 5 90 814676R1 DECEMBER 1996 Timing Synchronizing 8 Adjusting Specifications Full Throttle RPM Range Idle RPM in Forward Gear 5000 5500 600 700 3 10 30 BTDC 5500 RPM Throttle Primary Pick Up 2 BTDC 2 ATDC Throttle Secondary Pick Up 30 BTDC Recommended Spark Plug NGK BUHW 2 Fring Order Maximum Timing Special Tools PartNo Description 91 99379 Timing Light 91 63998A1 Spark Gap Tester Timing Adjustments STATIC TIMING OUTBOARD NOT RUNNING IMPORTANT On ELECTRIC START MODELS outboard battery MUST BE FULLY CHARGED when making timing checks MANUAL START MODELS MUST BE RUNNING in order to make any timing checks ELECTRIC START MODELS 1 Remove top cowling 2 Remove spark plug leads from spark plugs and remove spark plugs from outboard NOTE Removing spark plugs eliminates possibility of outboard accidentally starting and also allows starter motor to turn outboards over faster thus pro viding more accurate timing readings 90 814676R1 DECEMBER 1996 3 Install SPARK GAP TESTER 91 63998 1 be tween No 1 TOP spark plug lead and engine ground 4 Connect TIMING LIGHT
72. Trim Harness 11 Secure trim harness with clamp as shown a Clamp MID SECTION 5E 45 MID SECTION MANUAL TILT SYSTEM DESIGN Il Table of Contents Page Manual Tilt System Components Design One and TWO 5F 1 Quicksilver Lubricant Sealant Application Points 5F 1 Torque Specification 5F 1 Manual Tilt System Components Design Three 5 2 Quicksilver Lubricant Sealant Application POMS sco 5F 2 Torque Specification 5F 2 Manual Tilt Flow Diagrams Design 1 5F 3 Manual Tilt Flow Diagrams Design 2 5F 8 Manual Tilt Flow Diagrams Design 3 5F 13 Hydraulic System Troubleshooting 5F 18 Troubleshooting Flow Chart 5F 19 Manual Tilt System Removal 5F 21 Manual Tilt System Disassembly 5F 22 Accumulator Removal 5F 22 Shock Rod Removal 5F 23 Shock Rod Disassembly 5F 24 Valve Block 5F 26 Valve Block Disassembly 5F 27 Manual Tilt System Cleaning and Inspection 5 28 Manual Tilt System Reassembly 5F 28 Valve Block Reassembly 5F 28 Valve Block Installation 5F 30 Shock Ro
73. acceleration 2 difficulty getting the boat on plane or 3 an increase in engine RPM at wide open throttle Check the impeller blades occasionally for damage Use a flat file to resharpen the leading edges as shown 90 814676R1 DECEMBER 1996 Liner Replacement 1 Markthe liner mounting bolts for reassembly into the same holes Remove the bolts 2 Remove the liner If the liner is tight tap on the in ner edge of the liner with a long drift punch through the intake grate NOTE Apply grease to the liner mounting bolt threads before assembly 3 Position the liner into the water intake housing Line up one of the liner bolts and lightly thread it in It may be necessary to tap or press the liner into the water intake housing to locate the liner for installation of the remaining bolts Torque bolts to 100 Ibs in 11 2 N m 4 Grind off the ends of any bolts that may extend be yond the inner liner surface om 90 814676R1 DECEMBER 1996 Jet Drive Removal and Installation REMOVAL 1 Remove 2 locknuts and bolt securing jet drive to drive shaft housing and remove jet drive INSTALLATION 1 2 Install the exhaust tube seal into the jet drive Install jet drive with bolt and locknuts as shown Locknut and Washer 2 Torque to 60 Ib ft 81 4 N m Bolt Apply Loctite to Threads and Torque to 22 5 Ib ft 80 5 N m Seal Exhaust Seal LOWER UNIT 6B 11 Water Pump Removal and I
74. aligned with rod correctly Refer to connect ing rod cap alignment following Side View Side View Correct Incorrect End View End View Correct Incorrect b Clean CRANKSHAFT END of connecting rod by using 320 CLOTH placed in a slotted 3 8 9 5mm diameter shaft as shown Chuck shaft in a drill press and operating press at high speed while keeping connecting rod at a 900 angle to slotted shaft IMPORTANT Clean connecting rod just enough to clean up bearing surfaces DO NOT continue to clean after marks are removed from bearing surfaces 51083 4 30 POWERHEAD c Clean PIN END of connecting rod using same method as in Step b preceding using 320 grit carborundum cloth d Thoroughly wash connecting rods to remove abrasive grit Recheck bearing surfaces of connecting rods Replace any connecting rod s that cannot be properly cleaned up Lubricate bearing surfaces of connecting rods which will be re used with light oil to prevent rust Crankshaft 1 Inspect crankshaft to drive shaft splines for wear Replace crankshaft if necessary 2 Check crankshaft for straightness Replace as necessary 3 Inspect crankshaft oil seal surfaces Sealing sur faces must not be grooved pitted or scratched Replace as necessary 4 Check all crankshaft bearing surfaces for rust water marks chatter marks uneven wear and or overheating Refer to Connecting Rod Step 3 preceding
75. apply Loctite 271 to threads of nut adding or subtracting 001 in 0 025mm shim the backlash will change approximately 00125 in 0 032 mm Water Pump Reassembly and Installation 1 Apply 2 4 C Marine Lubricant on I D of oil seals 2 Press seals into water pump base a Narrow Seal Lip Away from Mandrel b Wide Seal Lip Toward Mandrel c Mandrel LOWER UNIT 6A 23 GQ 3 Install gasket a and O ring b 5 Install seal and washer Apply Quicksilver 2 4 C Marine Lubricant to 1 0 of insert and seal 54813 54755 4 Coat insert area of water pump body with Quick a Cupped Nylon Washer Cupped Side Towards Seal silver 2 4 C Marine Lubricant and install insert a b Seal making sure locating tab b enters hole in body c Insert Wipe off excess lubricant 6 Install components as shown 54814 54758 Water Pump Base Gasket Face Place Gasket 6A 24 LOWER UNIT 90 814676R1 DECEMBER 1996 A IMPORTANT When performing gear housing re 10 Install locking nuts and washers a and centrifu pair that requires removal of water pump impel gal slinger b ler it is recommended that the impeller be re placed If it is necessary however to re use the impeller DO NOT install in reverse to original rotation or premature impeller failure will occur Original rotation is clockwise 7 Install impeller drive key and impeller b
76. c Sand the commutator lightly with No 00 sandpaper to remove burrs then clean the commutator d Recheck the armature on a growler for shorts as specified in the following proce dure Testing 9 Open circuited armatures often can be saved where an open circuit is obvious and repairable The most likely place for an open circuit is at the commutator bars as a result of excessively long cranking periods Long cranking periods over heat the starter motor so that solder in the con nections melts and is thrown out The resulting poor connections then cause arcing and burning of the commutator bars 2B 12 ELECTRICAL AND IGNITION 10 Repair bars that are not too badly burned by soldering the leads in bars using rosin flux sol der and turning down the commutator in a lathe to remove burned material then undercut the mica 11 Clean out the copper or brush dust from slots be tween the commutator bars 12 Checkthe armature for ground See the following procedure Testing Testing ARMATURE TEST FOR SHORTS Check armature for short circuits by placing on growl er and holding hack saw blade over armature core while armature is rotated Recheck after cleaning be tween commutator bars If saw blade still vibrates re place armature 11669 Armature Tests for Shorts Bosch ARMATURE TEST FOR GROUND 1 Set VOA meter to R x 1 scale Place one lead of VOA meter on armature core or sha
77. caps to cylinder block and crankcase cover a Bolts a Bolts b Lower End Cap 90 814676R1 DECEMBER 1996 6 Bend back lock tabs on reed cage bolts and cen ter main bolt N 7 4 ns NC Locking Tab Washer b Reed Cage Bolt Center Main Bolt 7 Remove 17 bolts securing crankcase cover to block a Crankcase Cover 54685 POWERHEAD 4 17 8 Using pry points to aid in removal lift crankcase cover from cylinder block OSS K SNN N NES m 0 2 YE E 21872 54686 lt Lower End Cap b Crankcase Cover 10 Remove oil pump drive gear electric start mod 9 Gently tap upper and lower end caps from crank els only from crankshaft Gear slides off crank shaft with rawhide mallet shaft 54689 j EV Ey a Oil Pump Drive Gear 1 Upper End Cap 54687 4 18 POWERHEAD 90 814676R1 DECEMBER 1996 1 11 Re
78. factory and requires no additional lubrication at initial installation 1 Lubricate inside of outboard tilt tube a and en tire steering cable end b with Quicksilver 2 4 C Marine Lubricant 2 Insert steering cable end thru outboard tilt tube and secure steering cable to tilttube with steering cable attaching nut c as shown Torque nutto 35 Ib ft 41 N m 50579 3 Place a mark a on tilt tube 1 4 in 6 4mm from starboard end of tube Slide plastic spacer b O ring c and cap d over steering cable end to tilt tube on outboard 50325 4 Thread cap d onto tilt tube up to mark a 50325 90 814676R1 DECEMBER 1996 c i Installing Steering Link Rod Steering link rod MUST BE secured between out board steering arm bracket and steering cable end using special washer head bolt P N 10 14000 and two nylon insert locknuts P N 11 34863 as shown Both special washer head bolt and nylon insert locknuts MUST BE tight ened as specified Lubricate hole in end of steering cable with Quicksil ver 2 4 C Marine Lubricant Assemble steering link rod to steering cable end using 2 flat washers and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 14 N m of torque then back nut off 1 4 turn Lubricate ball joint in steering link rod with SAE 30W Motor Oil Secure link rod to outboard steering arm using special washer head bolt P N 10 14000 pro vided and nyl
79. so that tabs are aligned with gear housing center line Refer to If Necessary Adjust Trim Tab as Follows following a Operate boat at normal cruise throttle setting and adjust trim to optimum setting b If boat pulls to the right starboard trailing edge of trim tab must be moved to the right when viewing outboard from behind If boat pulls to the left port trailing edge of trim tab must be moved to the left 2 f necessary adjust trim tab as follows a Shift outboard into neutral and make sure ignition key is at OFF position b Remove plastic cap from rear of drive shaft housing and loosen bolt and trim tab 7 14 OUTBOARD MOTOR INSTALLATION ATTACHMENTS IMPORTANT tabs MUST BE set the same position on both outboards If boat pulls to the right adjust trailing edges of both trim tabs to the right If boat pulls to the left adjust trailing edges of both trim tabs to the left d Tighten both trim tab bolts securely and re place plastic caps e Operate boat per Check Trim Tab Position as Follows preceding to check trim tab set ting Readjust trim tabs if necessary Maintenance Instructions Maintenance inspection is the owner s responsibility and must be performed at intervals specified Normal Service Every 50 hours of operation or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation i
80. spacer and bushing prior to re NOTE Servicing components such as steering arm assembly driveshaft housing exhaust assembly etc generally require powerhead and or gear housing removal Refer to appropriate section in service manual Com ponents such as swivel bracket transom bracket lower mount bracket tilt tube and lower engine mounts can be serviced without powerhead gear housing removal however outboard must be sup ported shown before servicing components not re quiring powerhead gear housing removal Failure to support outboard as shown could re sult in personal injury and or damage to out board or boat Typical Outboard Shown 51079 Spring Tilt Lock Lever Bushing Spring Lever Roll Pin 0 2 Install roll pin to tilt lock lever assembly using propriate punch a Hoist b Rope Lifting Eye P N 91 90455 NOTE Refer to parts views on pages 1 2 and 3 and disassemble mid section components as required 91978 CAUTION When reinstalling outboard tilt tube longer threaded end of tilt tube must extend approxi mately 3 4 in 19mm toward steering cable nut side of boat 5A 4 MID SECTION 90 814676R1 DECEMBER 1996 outboard tilt tube using Quicksilver 6 Install and secure yoke and washer using snap 2 4 C Marine Lubricant and install into swivel ring bracket 4 Secure transom brackets into place using fiber washers and lock nuts
81. subtract 4 points 004 from the reading Example A hydrometer reading of 1 272 at 0 F 18 C would be 1 240 corrected to 80 F indicating a partially charged battery SPECIFIC GRAVITY CELL COMPARISON TEST This test may be used when an instrumental tester is not available To perform this test measure specific gravity of each cell regardless of state of charge and interpret results as follows If specific gravity read ings show a difference between highest and lowest cell of 050 50 points or more battery is defective and should be replaced 2B 2 ELECTRICAL AND IGNITION cM Check electrolyte level in battery regularly A battery in use in hot weather should be checked more fre quently because of more rapid loss of water If elec trolyte level is found to be low then distilled water should be added to each cell until liquid level rises approx 3 16 4 8mm over plate DO NOT OVER FILL because this will cause loss of electrolyte and result in poor performance short life and excessive corrosion CAUTION During service only distilled water should be added to the battery not electrolyte Electrolyte Level Liquid level in cells should never be allowed to drop below top of plates as portion of plates exposed to air may be permanently damaged with a resulting loss in performance Charging a Discharged Battery The following basic rule applies to any battery charg ing situation 1 Any battery mayb
82. ver Super Duty Lower Unit Lubricant 1 Tilt outboard so that lubricant in gear housing will drain toward front of housing out fill hole and into clean container IMPORTANT Inspect fill and VENT plug washers for damage Use new washer as needed 2 Remove lubricant fill plug and washer Note amount of metal particles on magnetic fill plug 3 Remove VENT plug with washer and allow suffi cient time for all lubricant to drain a Lubricant VENT Plug b Lubricant Fill Plug Washer 4 Inspect gear lubricant for metal particles lubri cant will have a metal flake appearance Pres ence of fine metal particles resembling powder on the drain plug bar magnet indicates normal wear The presence of metal chips on the drain plug bar magnet indicates the need for gear housing disassembly and components inspec tion 1 10 IMPORTANT INFORMATION PAS 5 Note color of gear lubricant White or cream color indicates presence of water in lubricant Gear lu bricant which has been drained from a gearcase recently in operation will have a yellowish color due to lubricant agitation aeration This is normal and should not be confused with the presence of water 6 Presence of water in gear lubricant indicates the need for disassembly and inspection of oil seals seal surfaces O rings water pump gaskets as well as gear housing components for damage IMPORTANT Never add lubricant to gear hous ing without first removing VENT
83. 13 Mercury Tilt Stop Switch Test 2 13 Flywheel Removal and Installation 2 14 Flywheel Removal 2 14 Manual Start Model 2 14 Electric Start Model 2 14 Flywheel Installation 2A 15 Ignition Components 2A 15 Stator Assembly Removal 2A 15 Black Stator Assembly Installation 2A 17 Red Stator Assembly Installation 2A 18 Trigger Plate Assembly Removal 2A 21 Trigger Plate Assembly Installation 2A 22 Ignition Coil Removal 2A 23 Ignition Coil Installation 2A 23 Switch Box Removal 2A 23 Switch Box Installation 2A 24 90 814676R1 DECEMBER 1996 Ignition System Black Stator Models Description The ignition system is alternator driven with distribu tor less capacitor discharge Major components of the ignition system are the flywheel stator assembly trigger assembly switch box ignition coils and spark plugs The stator assembly is mounted below the flywheel and has 2 coils The flywheelis fitted with permanent magnets inside the outer rim As the flywheel rotates the permanent magnets pass the stationary stator ignition coils This causes the ignition coils to pro duce AC voltage The AC voltage then is conducted to the switch boxes where it is rectified and stored in a capacitor The trigger assem
84. 2 4 C Marine Lubricant to lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into pivot pin hole and posi tion lower dowel pin retained in its hole 51148 a Lower Pivot Pin b Lower Dowel Pin 3 Reinstall manual tilt system bottom first Recon nect release valve link rod 51144 a Manual Tilt System 5G 34 MID SECTION 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a Lower Pivot Pin 5 Using a punch drive lower dowel pin in until seated a Lower Dowel Pin 90 814676R1 DECEMBER 1996 2 f 6 Apply 2 4 C Marine Lubricant 92 90018A12 to 8 Drive upper dowel pin a into its hole until seated surface of upper pivot pin pivot pin hole and shock rod hole a Dowel Pin 5114 Pivot Pin b Pivot Pin Bore 9 Check manual release cam adjustment Cam c Shock Rod Bore must open and close freely Adjust link rod as necessary 7 Using a mallet drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket Manual Release Valve Adjustment 1 With outboard in full up position place tilt lock lever forward 2 Lift cam lever with link rod to full up position a Pivot Pin Swivel Bracket Shock Rod o 51143 a Tilt Lock Lever b Cam Lever Link Rod 3 Link
85. 5 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51148 a Lower Dowel Pin 90 814676R1 DECEMBER 1996 6 Apply Special Lubricant 92 13872 1 to surface of upper pivot pin pivot pin bore and trim ram bore NOTE Install trim ram with cross hole located as shown Iftrim ram is installed reversed the trim send er if installed will not operate 51515 Cross Hole Transom Side Engine Side Pivot Pin Pivot Pin Bore Trim Ram Bore Install Trim Ram As Shown MID SECTION 50 27 A 1 7 Usinga suitable mallet drive upper pivot pin into 8 Drive upper retaining pin a in until seated swivel bracket and through trim ram until pivot pin is flush with swivel bracket 51505 9 Recheck fluid level 10 Power trim may now be operated to lower out a Pivot Pin board to desired position Trim system is self b Swivel Bracket purging Trim Ram 11 Reconnect power trim leads to relays under igni tion cover 12 Reinstall spark plug leads to spark plugs 13 Reinstall cowls 14 Connect battery leads to battery terminals 5D 28 MID SECTION 90 814676R1 DECEMBER 1996 MID SECTION POWER TRIM DESIGN 4 Table of Contents Page Special Tools
86. 80 Ib in 9 N m D B a JE Ej Y CO Screw 4 Torque to 80 Ib in 9 b Reservoir Reservoir Seal d Coupler e Manifold Assembly f Ground Strap 4 Fill reservoir to bottom of fill hole using Quicksil ver Power Trim Fluid 92 901000 12 If not available use automotive ATF automatic trans mission fluid 90 814676R1 DECEMBER 1996 p i Bleeding Power Trim Unit 1 2 90 814676R1 Secure power trim unit in soft jawed vise Add power trim fluid until even with the bottom of the fill hole Reinstall plug Close the manual release valve Turn full clock wise Reservoir Plug Fill Hole Manual Release Valve Using a 12 volt power supply connect the posi tive lead to blue trim motor wire and negative lead to green trim motor wire and drive shock rod to the up position Repeat for three times Connect the positive lead to the green trim mo tor wire and the negative lead to the blue trim motor wire and drive the shock rod to the down position Recheck fluid level add fluid if required and re peat cycle until fluid level stays even with the bot tom of the fill hole DECEMBER 1996 Installation of Power Trim System 1 2 Lubricate lower pivot pin mounting holes with 2 4 C Marine Lubricant Start lower pivot pin into pivot pin bore and posi tion lower dowel pin Retained in its r
87. Check Pilot Valve Assembly 5B 13 Leak Down Check Manual Release VEL GR REC 5 13 Leakage Past and Seat Piston Assembly 5B 13 Troubleshooting Flow Diagram 5B 14 Troubleshooting Flow Diagram 5B 15 Electrical System Troubleshooting 5B 16 COMMANDER 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 5B 16 Power Trim System Wiring Diagram 5B 17 Troubleshooting the Down Circuit When Up Circuit is 5B 18 Troubleshooting the Up Circuit When Down Circuit Is OK 5B 19 Troubleshooting the Down and Up Circuits All Circuits Inoperative 5B 20 Page Power Trim System Removal 5B 21 Power Trim System Disassembly 5B 22 Trim Rod 5B 22 Trim Rod Disassembly 5B 23 Trim Motor Removal 5B 25 Trim Motor Disassembly 5B 25 Reservoir Assembly Removal 5B 26 Oil Pump 5B 27 Manifold Removal 5B 27 Cleaning and Inspection of Trim Rod Components 5B 28 Motor and Electrical Tests Repair 5B 29 Trim Pump Motor 5B 29 Thermal Overload Switch Test 5B 29 Motor Assembled
88. DOWN d Engine Starter Motor Solenoid e Cowl Trim Switch f Fuse Holder 20 Amp Fuse g Engine Wiring Harness Connector h Remote Control Wiring Harness 90 814676R1 DECEMBER 1996 MID SECTION 5B 17 c Troubleshooting Down Circuit When Up Circuit is OK Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3 Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to There is an open circuit between Point 2 Point 3 and positive battery ter Depress Down trim button minal Checkforloose or corroded con nections Check wires for open Battery Voltage Indicated No Voltage Indicated Pump motor wiring is defective Relay Switch is defective e Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 5B 18 MID SECTION 90 814676R1 DECEMBER 1996 Troubleshooting the Up Circui
89. Holes and Press Together 90 814676R1 DECEMBER 1996 54702 a Torque Screws One Each Side to 55 Ib in 6 2 N m b Reed Block CAUTION Clean connecting rod bolts with solvent and dry with compressed air to prevent damage to threads while torquing DO lubricate threads prior to installation a Clean a sufficient amount of new connecting rod bolts with solvent and dry with com pressed air b Apply athin coat of Quicksilver Needle Bear ing Assembly Lubricant to crank pin bearing surface of connecting rod and rod cap to hold needle bearings in place POWERHEAD 4 33 CAUTION Never inter mix new needle bearings with used bearings If any bearing requires replacement replace all needle bearings on c Place needle bearings 25 required around crank pin bearing surface of connecting rod and cap 54715 Connecting Rod Rod Cap Bolts Needle Bearings d Place connecting rod and cap together on crank pin e Apply Loctite Grade A 271 to rod bolt threads f Thread connecting rod bolts finger tight while checking for correct alignment of the rod cap 4 34 POWERHEAD Side View Side View Correct Incorrect End View End View Correct Incorrect Correct Connecting Rod Cap Alignment g Tighten connecting rod bolts using 1 4 12 point socket evenly in three progressive steps until torqued to 200 Ib in 22 5 N m h Check each connecting rod
90. INFORMATION 1 11 5 Flush or service engine as required Be sure ade quate cooling water is provided a Water must be discharged thru tell tale IMPORTANT Prevent engine overheating If wa ter flow is insufficient stop engine and deter mine cause before continuing b Flush until discharged water is clear In salt water areas run outboard 3 to 5 minutes c Stop engine before turning off water 6 Stop engine turn water off and remove flushing attachment from gear housing IMPORTANT While and after flushing keep out board in upright position until all water has drained from drive shaft housing to prevent wa ter from entering the powerhead via drive shaft housing and exhaust ports Following Complete Submersion Submerged engine treatment is divided into 3 distinct problem areas The most critical is submersion in salt water the second is submersion while running Salt Water Submersion Special Instructions Due to the corrosive effect of salt water on internal engine components complete disassembly is nec essary before any attempt is made to start the en gine Submerged While Running Special Instructions When an engine is submerged while running the possibility of internal engine damage is greatly in creased If after engine is recovered and with spark plugs removed engine fails to turn over freely when turning flywheel the possibility of internal damage bent connecting rod and or be
91. Kit 3 8 x 1 5 8 P N 10 90041 Torque to 20 Ib ft 27 1 h Special Washer P N 12 71970 Lock Nut Two Supplied Kit and with Steering Link P N 11 34863 Torque to 20 Ib ft 27 1 Special Washer Head Bolt P N 10 14000 Torque to 20 Ib ft 27 N m Supplied with Steering Link k Steering Eye Rubber Sleeve m Rubber Bushing n Jam Nut Torque to 20 Ib ft 27 1 Dual Steering Coupler 9 p Lock Nut Supplied with Steering LInk P N 11 34863 Torque Until it Seats Do Not Exceed 120 Ib in 13 6 of Torque then Back Off 1 4 Turn 90 814676R1 DECEMBER 1996 50137 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7 13 Ride Guide Steering Attachment Extension Couplers Required Coupler s Outboard Center Between Steering Eyes Line Distance Shown Below 2110 9 in 229mm Coupler 22 1 2 in thru 24 1 2 in 572mm thru 622mm 12 in 305mm Coupler 23 1 2 in thru 27 1 2 in 15 in 381mm Coupler b97mm thru 699mm Supplied with this Kit 26 1 2 in thru 30 1 2 in 673mm thru 755mm 18 in 457mm Coupler a 18 in 457mm Coupler P N 814951 4 b 15 in 381mm Coupler P N 814951 3 c 12 in 305mm Coupler P N 814951 2 d 9 in 229mm Coupler P N 814951 1 Trim Tab Adjustment DUAL OUTBOARD 1 Check trim tab position as follows IMPORTANT Initial trim tab setting for both out boards should be straight to rear of outboard
92. Lead not used Adapter Module WHITE GREEN Lead Adapter Module GREEN WHITE Lead Stator YELLOW Leads Terminal Block Harness Extension Secure to Terminal Block w screws retained j Caps k Adapter Module BLUE Lead Adapter Module BLUE WHITE Leads m Adapter Module BLACK Leads Torque bolt to 40 Ib in 4 5 N m 2 20 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 c i i Trigger Plate Assembly Removal 1 Remove top cowl 2 Remove 3 bolts securing rewind starter or fly wheel cover and remove or cover whichever is applicable 3 Remove flywheel as outlined in FLYWHEEL RE MOVAL AND INSTALLATION preceding 4 Remove 4 screws which secure stator assembly to upper end cap Lift stator off end cap and move to the side Remove locknut that secures link rod swivel into spark arm Pull link rod swivel out of arm LON 54648 Trigger Plate Assembly Link Rod Swivel Spark Arm Lock Nut Trigger Harness Sta Straps 90 814676R1 DECEMBER 1996 6 Remove 6 bolts from electrical box access cover and remove cover 54645 Bolts b Access Cover 7 Disconnect trigger leads form their respective terminals on switch box Remove trigger plate as sembly from engine
93. Manifold Installation IMPORTANT Install spring check valve and O ring into manifold Position components in place using sleeve to seat in place It is recommended that O ring and valve seat be replaced when in stalling Screw and Seal Kit 811226A1 in manifold 50999 Spring b O ring Sleeve d Valve Seat 90 814676R1 DECEMBER 1996 1 Install check valve components into manifold O ring 0 114 1 0 Spool O ring 0 301 1 0 3 each Sleeve Spring Valve Seat Valve Spring IMPORTANT Sleeve d is chamfered 1 0 on end opposite drilled cross hole Install spool e with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool 2 Install O rings on cylinder and secure manifold assembly to cylinder using screws Torque screws to 100 Ib in 11 0 N m 51486 a 05 2 MID SECTION 5D 21 b Screws 100 Ib in 11 N m 2 3 Secure power trim unit in soft jawed vise End Bushing Lubricate with Quicksilver 2 4 Lubricant Trim Motor Reassembly b Brush 2 c Commutator 1 Place brush tension springs on outer ends of d Brush Tension Spring 2 brush housings to release tension on brushes 3 Guide armature and motor frame into reservoir housing as shown a Brush Tension Spring 2 b Brush Housing 2 c Brush 2
94. RPM Running 130 Volts 195 to 275 Volts TEST RESULTS e Voltage output is high on all coils The adapter module is defective Replace adapter module e No voltage output or low voltage output on all coils Go to STEP 5 Stator Adapter Module and Switch Box Test Good voltage on two coils Go to Trigger Test Good voltage on all coils Go to Testing For Spark 90 814676R1 DECEMBER 1996 STEP 2 Stop Circuit Test BLK o YEL e 54 D Te etr E li a Ee Se 7 a Connect Test Lead To BLK YEL Wire Terminal On Switch Box b Connect Test Lead To Engine Ground 1 Use Multimeter Tester 91 99750 Set switch position to 400 2 Crank engine and observe meter reading Voltage at 300 RPM cranking Voltage at 1000 4000 RPM Running 190 Volts 275 to 320 Volts TEST RESULTS e Voltage output is high The adapter module is de fective Replace adapter module e Good voltage output Goto STEP 3 Switch Box BLU Wire Circuit Test e No voltage output or low voltage output Remove BLK YEL wires from switch box terminal and re peat test If voltage output is now OK either the ignition switch stop switch or wiring is defective If no voltage or low voltage remains go to STEP 5 Stator Ad
95. Release Valve 5D 18 MID SECTION 90 814676R1 DECEMBER 1996 3 Remove four screws securing reservoir to man ifold a Screws 4 4 Remove reservoir from manifold 5 Remove drive shaft from oil pump a Reservoir b Drive Shaft c Oil Pump 90 814676R1 DECEMBER 1996 Manifold Removal 1 Remove screws and manifold from cylinder 51007 a Trim Cylinder b Manifold c Screw 2 2 Remove check valve components from manifold IMPORTANT Sleeve d is chamfered on 1 0 on end opposite drilled cross hole Install spool b with O ring installed from chamfered end of sleeve to avoid possibility of damaging O ring on spool O ring 0 114 1 0 Spool O ring 0 301 1 0 3 each Sleeve Spring Valve Seat Valve Spring MID SECTION 50 19 3 Remove O rings from cylinder 51008 a 05 2 Cleaning and Inspection of Trim Rod Components CAUTION Do not remove check ball components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam age 51199 Inspect check valve for debris clean debris form check valve if found If debris cannot be cleaned from check valve replace trim rod piston as an assembly Clean trim rod and components with parts cleaner and dry with compressed air It is recommended that all O ring
96. Remove top cowl 2 Remove 6 bolts from electrical box access cover and remove cover Ignition Coil Installation 1 Install spark plug high tension lead coil tower boot assembly retained onto new coil Position secondary coil into electrical box Reconnect positive and negative leads to their respective terminals on coil with 2 nuts a Bolts b Access Cover 3 Disconnect wires from positive and negative 7 terminals on defective coil Remove spark plug boot from spark plug 5 Remove spark plug high tension lead coil tower boot assembly from coil tower and discard defec tive coil Torque nuts to 30 in 3 4 N m Reconnect spark plug boot to spark plug 5 Reinstall electrical box access cover and secure cover with 6 bolts 6 Reinstall top cowl Switch Box Removal 1 Remove top cowl 2 Remove 6 bolts from electrical box access cover and remove cover a Bolts G Positive Lead Negative Lead High Tension Lead Coil Tower Boot Coil 90 814676R1 DECEMBER 1996 b Access Cover 54650 ELECTRICAL AND IGNITION 2A 23 3
97. Seal throughout cylinders Reinstall spark plugs 5 If engine fuel filter appears to be contaminated remove and replace Refer to Section 3 Fuel System and Carburetion 6 Drain and refill lower unit with Quicksilver Gear Lube as explained in Gear Housing Lubrication see Table of Contents 7 Clean outboard thoroughly including all accessi ble powerhead parts and spray with Corrosion and Rust Preventive 8 Refer to lubrication chart in this section see Table of Contents and lubricate all lubrication points 9 Remove propeller Apply Special Lubricant 101 Anti Corrosion Grease or 2 4 C Marine Lubricant to propeller shaft and reinstall propeller Refer to Propeller Installation see Table of Contents 90 814676R1 DECEMBER 1996 10 If the water pickup is clogged the speedometer will be inoperative Clean the pickup with a piece of wire or blow out with compressed air Before blowing out with air disconnect the tubing from the speedometer 11 To prevent freeze damage drain the speedome ter system of water completely before storage Remove tubing from speedometer fitting and blow thru the tubing to remove water 12 Store battery as outlined in Dut of Season Bat tery Storage following 13 For out of season storage information on Auto Blend units refer to Section 8 in this service manual IMPORTANT When storing outboard for the win ter be sure that all water drain holes in gear hous
98. Season Outboard Storage 1 13 Out of Season Battery Storage 1 13 How Weather Affects Engine Performance 1 14 Conditions Affecting Operation 1 15 Detonation Causes and Prevention 1 15 Compression Check 1 16 Painting Procedure 1 17 Decal 1 18 gt 90 814676R1 DECEMBER 1996 AA Propeller Information For in depth information on marine propellers and boat performance written by marine engineers see your Authorized Dealer for the illustrated What You Should Know About Quicksilver Propellers and Boat Performance Information Part No 90 86144 How to Use this Manual The manual is divided into SECTIONS shown right which represents major components and systems Some SECTIONS are further divided into PARTS Each PART has atitle page A Table of Contents for the particular PART is printed on the back of the title page SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately follows the cover of this book Section Section Heading Important Information Electrical and Ignition Fuel System and Carburetion Powerhead Mid Section Lower Unit Outboard Installation Attachments Oil Injection System ONOaBRWN 90 814676R1 DECEMBER 1996 IMPORTANT INFORMATION 1 1 EY General Specifications 1 Re
99. Special Lubricant 101 to lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into pivot pin hole and posi tion lower dowel pin retained in its hole 51148 a Lower Pivot Pin b Lower Dowel Pin 90 814676R1 DECEMBER 1996 MID SECTION 5F 35 3 Reinstall manual tilt system Reconnect release valve link rod 51144 a Manual Tilt System 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a Lower Pivot Pin 5 Using a punch drive lower dowel pin in until seated X N 51148 a Lower Dowel Pin 5F 36 MID SECTION 6 Apply 2 4 Marine Lubricant 92 90018 12 to surface of upper pivot pin pivot pin hole and shock rod hole 51148 Pivot Pin Pivot Pin Bore Shock Rod Bore N oon Using a mallet drive upper pivot pin into swivel bracket and through shock rod until pivot pin is flush with swivel bracket Pivot Pin Swivel Bracket Shock Rod oom Drive upper dowel pin a into its hole until seated a Dowel Pin 9 Check manual release cam adjustment Cam must open and close freely Adjust link rod as necessary 90 814676R1 DECEMBER 1996 MID SECTION MANUAL TILT SYSTEM DESIGN 4 Table of Contents Special Tools jx m Tilt DOWN Slow Tilt Down Under High Thrust
100. Tight but SCREW 2 IN tuator must be free to pivot WASHER WAVE WASHER PLATE SCREW 1 2 IN SCREW 1 IN NUT CAP SCREW 7 8 IN SPRING NUT SPARK ADVANCE LEVER SCREW 1 3 4 IN Drive Tight BUSHING BUSHING SPRING WASHER SCREW 1 3 4 IN NUT CAP LINK ROD PIVOT SWIVEL BALL SWIVEL BASE SCREW 2 1 4 IN SCREW 1 3 4 IN NUT CAP LATCH 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 90 814676R1 DECEMBER 1996 POWERHEAD 4 3 Cylinder Block and Crankcase Assembly CD 3 alg S Ka k E A NS ERES AV T 1 SE 4 212 A gt 4 aa 5 VW 5 2 9 st gob 8 NA NT N 8 gt A z iem X o 25 5 Ce eof 958585 ry e SN N 90 814676R1 DECEMBER 1996 4 4 POWERHEAD Cylinder Block and Crankcase Assembly TORQUE QTY DESCRIPTION Ib in Ib ft CYLINDER BLOCK CRANKCASE ASSEMBLY BRACKET starter motor UPPER SCREW bracket to crankcase 1 7 8 LOCKWASHER bracket screw COVER starter motor LOWER SCREW cover to crankcase 1 7 8 PLUG DOWEL PIN STUD carburetor 1 1 4 STUD c
101. a Punch b Insert c Vise IMPORTANT When performing gear housing re pairs that require water pump impeller removal it is recommended that the impeller be replaced If impeller must be reused DO NOT install in re verse to original rotation or premature impeller failure will occur Original rotation is clockwise 90 814676R1 DECEMBER 1996 6 Remove impeller a and drive key b from drive shaft If necessary use a punch and hammer to drive impeller upward off drive shaft In extreme instances the impeller center hub must be split with chisel Take care not to damage drive shaft 7 Remove gaskets a and face plate b 8 Inspect face plate for grooves If grooved re place face plate LOWER UNIT 6A 7 9 Remove water pump base and gasket 10 Inspect base and replace if cracked distorted or melted 54759 a Water Pump Base b Shop Cloths Screwdrivers 11 Remove and discard seals a and O ring b 54760 8 LOWER UNIT Q Bearing Carrier and Propeller Shaft Removal IMPORTANT For proper retention between hous ing and cover nut it is recommended that PLAS TIC cover nut NOT be reused Replace as re quired 1 Bend lock tab a away from cover nut slot KO p a Cover Nut Tool 91 91947 90 814676R1 DECEMBER 1996 3 Remove bearing carrier from gear housing using 6 Remove cross pin pullar duis ano
102. acceptable disconnect the two red leads coming from the voltage regulator rectifier Connect the smaller diameter red lead to the terminal of a 9 volt transistor battery Connect the negative terminal of the 9 volt battery to en gine ground 2B 6 ELECTRICAL AND IGNITION Connect RED ammeter lead to larger diame ter RED lead and BLACK ammeter lead to POSITIVE on starter solenoid With engine running at the indicated RPM the ammeter should indicate the following approxi mate amperes 9 Amp Black Stator 16 Amp Black Stator 16 Amp Red Stator If ammeter reads less than required amperes test the stator If stator tests OK replace voltage regulator rectifier 90 814676R1 DECEMBER 1996 p n Rectifier Test Disconnect battery leads from battery before testing rectifier 1 To gain access to rectifier remove 6 bolts from electrical box cover and remove cover NOTE Rectifier can be tested without removing from engine the following test 54645 a Bolts a Terminal b Terminal c Terminal d Alternator Terminals e Positive Terminal f Ground 2 Disconnect all wires from terminals on rectifier 3 Use an ohmmeter R x 1000 scale and perform b Cover Connect red meter lead to ground black lead alternately
103. and at bottom of stroke Use straight ring compressor b No 2 piston must be straight out from crank pin throw and at top of stroke Use a straight compressor c 3 and 4 pistons must be directly in line with upper pistons and use offset ring compressors d Check piston ring end gap alignment all pis tons with locating pins POWERHEAD 4 39 54724 a Straight Compressors b Offset Compressors Ring Compressors Installed on Pistons Front View a Straight Compressors b Offset Compressors Ring Compressors Installed on Pistons Rear View 4 40 POWERHEAD 90 814676R1 DECEMBER 1996 fn 4 removed place reed block locating pins into cylinder block a Reed Block Locating Pin b Main Bearing Support Locating Pin on Some Models Pin is Located in Bearing Support c Lubricate Cylinder Walls Pistons and Piston Rings with Light Oil 5 Install crankshaft assembly into cylinder block Remove ring compressors as each piston enters cylinder Make sure that crankshaft is kept hori zontal while installing 54727 a Keep Crankshaft Horizontal 90 814676R1 DECEMBER 1996 6 Align centermain bearing and re
104. and reassembling rewind starter SAFETY GLASSES must be worn in case rewind spring uncoils out of the housing 1 Untie knotin starter rope and release starter rope to allow rewind spring to unwind 2 Removeretaining clip and attaching screw which secures shift interlock cable to starter housing 3 Remove rewind starter from engine a Shift Interlock Cable b Cable Attaching Screw c Retaining Clip 7 2 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 90 814676R1 DECEMBER 1996 7 Remove spring retaining plate 9 Remove rewind spring by placing sheave over 2 XXX pieces of wood 2 x 4 s with spring facing down Tap top of sheave with a mallet This will cause rewind spring to drop out of sheave Cleaning and Inspection 1 Clean components in solvent and dry with com pressed air 2 Inspect rewind spring for kinks burrs corrosion or breakage 3 Inspect starter sheave rope guide and starter housing for nicks grooves cracks wear or dis tortion especially area of rope travel 4 Inspect bushing starter drive pawl and spring for wear or damage 54848 Inspect starter rope for wear Replace components as necessary 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7C 3 Rewind Starter Reassembly When reassembling rewind starter SAFETY GLASSES must be worn in case rewind spring unco
105. assemble unit completely and replace all O rings Check ball valve components and cast ings must be cleaned using engine cleaner and compressed air or replaced prior to reassembly Power trim system is pressurized Outboard must be in the full UP position cylinder fully extended prior to fill screw or manual release valve removal Refer to instructions following if disassembly is re quired Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks Operate Power Trim System after each check to see if problem is corrected If not proceed with the next check 1 Check that manual release valve is tightened to full right clockwise position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Fill and Purge the Power Trim System 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls to trim in position indicates debris or defective compo nents in trim valve assembly Clean or replace components as required 5 Check manual release valve for broken stem one O ring remaining in the release valve pas sage Separate the manifold assembly from the cylinder to dislodge broken stem Install new re lease valve and test system 6 Check for nicked deteriorated or misplaced O rings throughout trim system 90 814676R1 DECEMB
106. blow air thru all passages orifices and nozzles 4 Check float hinge in the float pin area for wear and check float for leaks Replace parts as nec essary 5 Examine inlet needle for wear If worn replace with new inlet needle a Screws b Throttle Shaft 90 814676R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 25 Q Carburetor Reassembly 3 Install throttle return spring to throttle shaft 1 Install throttle shaft to carburetor 52021 a Throttle Shaft 52016 2 Install throttle shaft plate to throttle shaft Apply As Tarola spring b Throttle Shaft Loctite 271 to threads of screws Tighten secure ly 4 Install idle mixture screw and spring in carbure tor Refer to Idle Mixture Screw Adjustment preceding a Throttle Shaft Plate b Screws 52015 a Idle Mixture Screw b Spring 3 26 FUEL SYSTEM AND CARBURETION 90 814676R1 DECEMBER 1996 p 14 5 Install vent jet Torque to 14 Ib in 1 6 52015 a Vent Jet Torque to 14 Ib in 1 6 N m 6 Install main jet Torque to 6 Ib in 0 7 WMATB CARB 52016 52026 a Main Jet Torque to 35 Ib in 3 9 N m 90 814676R1 DECEMBER 1996 7 Install venturi into carburetor Install main nozzle into carburetor Tighten securely 52015 a Venturi b Main Nozzle 8 Install float needle float and baffle plate Secure needle to float using retaining wire on float needle
107. bolt 7 Remove remaining components from propeller shaft 54763 a Bearing Carrier 54766 b Puller Jaws 19 46086A1 c Puller Bolt 91 85716 a Punch b Cross Pin Sliding Clutch 4 Remove propeller shaft from gear housing d Cam Follower S 8 Inspect cam follower for pitting scoring or rough surface replace cam follower AND shift cam if damage to cam follower has occurred 9 Remove reverse gear using puller S 54764 5 Remove spring a from sliding clutch 54767 a Puller 91 27780 54765 90 814676R1 DECEMBER 1996 LOWER UNIT 6A 9 10 Inspect reverse gear bearing If bearing is rusted or does not roll freely replace bearing N 54768 Universal Puller Plate 91 37241 b Mandrel 91 37312 Bearing on Reverse Gear 54769 a Puller 91 27780 Bearing in Bearing Carrier 6A 10 LOWER UNIT p i 11 Inspect bearing a If bearing is rusted or does a b not roll freely replace bearing 54770 Mandrel 91 24273 Drive Shaft Pinion Gear Removal 1 Place gear housing assembly in to padded vise as shown Remove pinion nut Remove
108. bolts flat washers and locknuts as shown Be sure that in stallation is water tight Tighten Transom Clamp Handles 1 2 Inch Diameter Bolts 4 Flat Washers 4 Locknuts 4 Marine Sealer CAUTION Marine sealer must be used shanks of mount ing bolts to make a water tight installation OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7 3 Single Cable Single Outboard Ride Guide Steering Attaching Kit P N 19608A3 and P N 19609A2 Installation Component Removal Tiller Handle Models Remove and discard tiller handle assembly spacer and mounting studs from outboard steering arm as outlined in appropriate outboard service manual Steering Bracket Installation Tiller Handle Models Secure supplied steering bracket to outboard steer ing arm Outboard Steering Arm Steering Bracket Locking Retainer Bolt 2 7 8 in 22mm Long Torque to 40 Ib ft 54 N m Then bend corner tabs of locking retainer up against flats on each bolt om Locking retainer corner tabs MUST BE bent up and against flats on each bolt that secures steer ing bracket to outboard steering arm to prevent bolts from turning out 7 4 OUTBOARD MOTOR INSTALLATION ATTACHMENTS c 19608A 3 Ride Guide Steering Attaching Kit Installation Steering Cable Routed for Starboard Entry into Outboard Tilt Tube Refer to Quicksilver Accessories Guide to deter mine corr
109. by the service procedure selected All information illustrations and specifications con tained in this manual are based on the latest product information available at the time of publication As re quired revisions to this manual will be sent to all deal ers contracted by us to sell and or service these prod ucts It should be kept in mind while working on the prod uct that the electrical system and ignition system are capable of violent and damaging short circuits or se vere electrical shocks When performing any work where electrical terminals could possibly be grounded or touched by the mechanic the battery cables should be disconnected at the battery Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive inter nal damage when the engine is started Itis important to note during any maintenance proce dure replacement fasteners must have the same measurements and strength as those removed Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength Ameri can bolts use radial lines for this purpose while most American nuts do not have strength markings Mis matched or incorrect fasteners can result in damage or malfunction or possibly personal injury There fore fasteners removed should be saved for reuse in the same locations whene
110. end must be ful ly retracted into cable housing before lubricating cable If cable is lubricated while extended hy draulic lock of cable could occur 3 With core of Ride Guide Steering cable transom end fully retracted lubricate transom end of steering cable thru grease fitting and exposed portion of cable end with 2 4 C Marine Lubricant Lubricate all pivot points with SAE 30W engine oil OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 7 Single Cable Dual Outboard Ride Guide Steering Kit P N 97933A4 Installation Dual outboard installation requires steering bracket replacement P N 19617 from kit Upon completion of steering bracket replace ment locking retainer corner tabs must be bent up and against flats on each bolt that secures steering bracket to outboard to prevent bolts from turning out 1 Remove and retain steering bracket bolts and locking retainer Discard original steering brack et 2 Attach steering bracket from kit to outboard steering arm with retained bolts and locking re tainer 3 Torque bolts to 40 Ib 54 and bend tabs of locking retainer up against flats of bolts 50579 a Locking Tabs Bent Into Place b Bolts Torque to 40 Ib ft 54 N m Steering Bracket 7A 8 OUTBOARD MOTOR INSTALLATION ATTACHMENTS Installation Requirements IMPORTANT The distance from each outboard s centerline to the side of transom opening or gun nel MUST BE a minimum of 16 i
111. end of piston pin tool with mallet push ing piston pin out of piston Remove piston from connecting rods Piston Pin Tool 91 76160A2 Piston Pin Support Piston Up While Forcing Piston Pin Out Remove piston pin needle bearings and locating washers from connecting rod a Needle Bearings 27 Required b Locating Washers POWERHEAD 4 23 IMPORTANT It is recommended that new needle bearings be installed in connecting rod to ensure lasting repair NOTE If needle bearings must be reused store them in numbered container so they can be rein stalled with same connecting rod DO NOT intermix needle bearings from one connecting rod with those from another connecting rod Keep needle bearings clean 6 Remove and discard connecting rod bolts Sepa rate connecting rod from rod cap Remove con necting rod cap and needle bearings from crank pin throw Keep connecting rod cap and needle bearings together if they are to be reused a Screw and Nut One Each Side b Reed Block LY toe 4 b K o gt A Se ay z 54701 Connecting Rod Connecting Rod Cap Connecting Rod Bolts Needle Bearing 25 Required N Remove two screws and locknuts which secure both halves of reed block together
112. f Wiring Diagram Model 40 Electric Start with 16 Amp Black Stator BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT BLU LIGHT BLUE Stator Trigger Switch Box Voltage Regulator Starter Starter Solenoid Battery To Bottom Cowl To Tan Female Connector on Remote Control Harness Plug 10 Temperature Gauge Sender 11 Warning Module 12 Overheat Module 20 6 ELECTRICAL AND IGNITION YEL B EL RED 7 52468 13 Low Oil Switch 14 Coil No 1 15 Coil No 2 16 Coil No 3 17 Coil No 4 18 20 Ampere Fuse 19 Fuel Enrichment Valve 90 814676R1 DECEMBER 1996 aX Wiring Diagram Model 40 Electric Start with 16 Amp Red Stator BLK Black GEER BLU Blue GRY Gray GRN Green ORN Orange 7 PNK Pink P PUR Purple S RED Red Tan Tan WHT White Le YEL Yellow z LIT Light Dark RED YEL D WI 5 YEL Cp VEL RED CoD VEL BLU NHT BLUMWHT Cto Ce BLU pj 2 BLK GRY YEL BL 54947 16 Ampere Stator Stator Adaptor Voltage Regulator Switch Box Ground Connection 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 7 Wiring Diagram Model 40 Electric Start Handle with 1
113. hammer m a Slide Hammer 91 34569 b Bearing Race c Shim s 6A 12 LOWER UNIT Q 4 Replace bearing a if it is rusted or does not roll freely Use punch and hammer to remove bear ing 19203 Shift Shaft Removal 1 Remove shift shaft bushing 2 Remove shift shaft b and shift cam c from gear housing P 9 54777 Shift Shaft Bushing Tool 91 23033 b Shift Shaft c Shift Cam 90 814676R1 DECEMBER 1996 p i 3 components from shift shaft Drive Shaft Needle Bearing Removal 1 If bearing is rusted or does not roll freely replace bearing lt lt 91 37312 SI b Needle Bearing 54778 a Rubber Washer b Bushing 2 Cleaning and Inspection d E Clip e Shift Cam i Gear Housing Bearing Carrier 4 Remove and discard seal a and O ring b Castings 1 Thoroughly clean gear housing bearing carrier castings Be sure all old gasket material is re moved from mating surfaces and that carbon de posits have been removed from exhaust pas sages Inspect castings for cracks or fractures Check sealing surfaces for nicks deep grooves and distortion which could cause leaks 4 Ch
114. high speed reduce the power gradually and trim the motor In slightly before resuming high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instabili ty 90 814676R1 DECEMBER 1996 Will lift bow of boat usually increasing top speed Transfers steering torque harder to port left on in stallations below 23 in transom height Increases clearance over submerged objects In excess can cause porpoising and or ventilation In excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow erhead overheating damage Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up relay lo cated under engine cowl and close the electric motor circuit The electric motor drives the pump forcing fluid thru internal passageways into the up side of the trim cylinder The trim cylinder trim ram will position the engine at the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum tr
115. ing are open and free so that all water will drain out If a speedometer is installed in the boat dis connect the pickup tube and allow it to drain Re connect the tube after draining Trapped water may freeze and expand thus cracking gear hous ing and or water pump housing Check and refill gear housing with Quicksilver Gear Lube before storage to protect against possible water leak age into gear housing which is caused by loose lubricant vent plug or loose grease fill plug In spect gaskets under lubricant vent and fill plugs replacing any damaged gaskets before reinstal ling plugs Out of Season Battery Storage 1 Remove battery as soon as possible and remove all grease sulfate and dirt from top surface 2 Cover plates with distilled water but not over 3 16in 56mm above perforated baffles 3 Cover terminal bolts well with grease Store battery ina COOL DRY place in a dry car ton or box 5 Remove battery from storage every 60 days Check water level and place on charge for 5 to 6 hours at 6 amperes DO NOT fast charge A CAUTION A discharged battery can be damaged by freez ing IMPORTANT INFORMATION 1 13 How Weather Affects Engine Performance Rated HP Horsepower Loss Due to Atmosphere Conditions Summer HP to Propeller Becom ing Too Large for Summer 7 77 Horsepower HORSEPOWER 1 Due to Weather ENGINE RPM Rated RPM It is a
116. known fact that weather conditions exert a pro found effect on power output of internal combustion engines Therefore established horsepower ratings refer to the power that the engine will produce at its rated RPM under a specific combination of weather conditions Corporations internationally have settled on adop tion of I S O International Standards Organization engine test standards as set forth in 1 5 3046 standardizing the computation of horsepower from data obtained on the dynamometer correcting all val ues to the power that the engine will produce at sea level at 3096 relative humidity at 77 F 25 C tem perature and a barometric pressure of 29 61 inches of mercury Summer Conditions of high temperature low baro metric pressure and high humidity all combine to re duce the engine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour in some cases Refer to previous chart Nothing will regain this speed for the boater but the coming of cool dry weather 1 14 IMPORTANT INFORMATION In pointing out the practical consequences of weath er effects an engine running on a hot humid sum mer day may encounter a loss of as much as 1490 of the horsepower it would produce on a dry brisk spring or fall day The horsepower that any internal combustion engine produces depends upon the density of the air that it consumes and in turn this density is dependent upon the te
117. liq uid in several times to ensure correct tempera ture before taking reading 4 Hold hydrometer vertically and draw in just enough liquid from battery cell so that float is free floating Hold hydrometer at eye level so that float is vertical and free of outer tube then take read ing at surface of liquid Disregard curvature where liquid rises against float stem due to capil larity 5 Avoid dropping electrolyte on boat or clothing as it is extremely corrosive Wash off immediately with baking soda solution Specific gravity of electrolyte varies not only with per centage of acid in liquid but also with temperature As temperature drops electrolyte contracts so that spe cific gravity increases Unless these variations in specific gravity are taken into account specific grav ity obtained by hydrometer may not give a true indica tion of concentration of acid in electrolyte A fully charged battery will have a specific gravity reading of approximately 1 270 at an electrolyte tem perature of 80 F 27 C If electrolyte temperature is above or below 80 F additions or subtractions must be made in order to obtain a hydrometer read ing corrected to 80 F standard For every 10 F 3 3 C above 80 F add 4 specific gravity points 004 to hydrometer reading Example A hydrometer reading of 1 260 at 110 F 48 C would be 1 272 corrected to 80 F indicating a fully charged battery For every 10 below 80 F
118. loss Clean surfaces when necessary 3 Gear Housing If unit is left in the water marine vegetation may accumulate over a period of time in certain types of water This growth must be re moved from unit before operation as it may clog the water inlet holes in the gear housing and cause the engine to overheat 90 814676R1 DECEMBER 1996 Detonation Causes and Prevention Detonation in a 2 cycle engine somewhat resembles the pinging heard in an automobile engine It can be otherwise described as a tin like rattling or plank ing sound Detonation generally is thought of as spontaneous ignition but it is best described as a noisy explosion in an unburned portion of the fuel air charge after the spark plug has fired Detonation creates severe un timely shock waves in the engine and these shock waves often find or create a weakness The dome of a piston piston rings or piston ring lands piston pin and roller bearings While there are many causes for detonation in a 2 cycle engine emphasis is placed on those causes which are most common in marine 2 cycle applica tion Afew which are not commonly understood are 1 Over advanced ignition timing 2 Use of low octane gasoline 3 Propeller pitch too high engine RPM below rec ommended maximum range Lean fuel mixture at or near wide open throttle Spark plugs heat range too hot incorrect reach cross firing 6 Inadequate engine cooling deteriorat
119. mandrel into gear until dimensions c is ob tained a Tab Position Towards Front of Gearcase Forward Gear and Bearing Reassembly a Needle Bearing b Gear c Bearing Flush with Shoulder to 020 in 508mm Recessed d Mandrel 91 37311 LOWER UNIT 6A 17 2 Press tapered bearing onto forward gear 54793 a Mandrel MUST Contact Inner Bearing Race Only 91 38628 b Inner Bearing Race MUST BE Tight Against Shoulder of Gear Wood Bearing Carrier Reassembly IMPORTANT Do not force bearing into carrier or damage may occur to bearing 1 Press needle bearing into bearing carrier until bearing edge is just below bearing carrier seal edge 6A 18 LOWER UNIT 54794 a Mandrel 91 37321 b Needle Bearing Seal Edge 2 Press bearing onto reverse gear until seated 77 d 54795 a Thrust Washer Beveled Side Toward Gear b Bearing c Mandrel 91 38628 d Wood 90 814676R1 DECEMBER 1996 3 Apply Loctite Grade onto of seals and press into bearing carrier Apply 2 4 C Marine Lubricant onto 1 0 of seals Lubricate O D of ball bearing with Quicksilver Needle Bearing Lubricant and press into bearing carrier 54796 a Fish Line Cutter Seal Cutter Seal
120. of throttle cable connected to throttle lever hold throttle lever against idle stop Adjust throttle cable barrel to slip into barrel retainer on cable anchor bracket with a very light preload of throttle lever against idle stop Lock barrel in place c Check preload of throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be removed with some drag but without tearing Readjust cable barrel if necessary IMPORTANT Excessive preload on throttle cable will cause difficult shifting from FORWARD to NEUTRAL Readjust throttle cable if necessary ELECTRICAL AND IGNITION 2C 5 ELECTRICAL AND IGNITION eun 31 vum veum im 9 PUR 2 PUR US Sive in m 18 RED i N A WIRING Table of Contents Page Wiring Diagram Model 30 Jet with 16 Amp Black Stator 2D 1 Wiring Diagram Model 30 Jet with 16 Amp Red Stator 2D 2 Wiring Diagram Model 30 Jet Tiller Handle with16 Amp Black Stator 2D 3 Wiring Diagram Model 30 Jet Tiller Handle with16 Amp Red Stator 2D 4 Wiring Diagram Model 40 Electric Start with 9 Amp Black Stator 2D 5 Wiring Diagram Model 40 Electric Start with 16 Amp Black Stator 2D 6 Wiring Diagram Mo
121. operation are major accident pre vention measures DANGER DANGER Immediate hazards which WILL result in severe personal injury or death WARNING Hazards or unsafe practices which COULD result in severe personal injury or death CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage Notice to Users of This Manual This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers mechanics and company service per sonnel when servicing the products described here in It is assumed that these personnel are familiar with the servicing procedures of these products or like or similar products manufactured and marketed by Mercury Marine that they have been trained in the recommended servicing procedures of these prod ucts which includes the use of mechanics common hand tools and the special Mercury Marine or recom mended tools from other suppliers 90 814676R1 DECEMBER 1996 We could not possibly know of and advise the service trade of all conceivable procedures by which a ser vice might be performed and of the possible hazards and or results of each method We have not under taken any such wide evaluation Therefore anyone who uses a service procedure and or tool which is not recommended by the manufacturer first must completely satisfy himself that neither his nor the products safety will be endangered
122. or open circuits Check battery charge No Voltage Indicated Check that voltage is being supplied to control by performing the following checks DO NOT start engine Turn ignition switch to po sition Check for voltage at any instru ment using a Voltmeter No Voltage Indicated Red wire is open between Point 3 and red terminal on back of the ig nition switch Checkforloose or corroded con nections Check for open in wire 5B 20 MID SECTION Check in line fuse under cowl to see if fuse is blown No Voltage Indicated Connect red Voltmeter lead to Point 5 and black lead to ground Fuse Not Blown Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated Battery Voltage Indicated Connect Voltmeter red lead to Point 8 and black lead to ground Depress Up trim button and check for battery voltage Battery Voltage Indicated Check black ground wires for poor connection or poor ground Pump motor is faulty Refer to Motor and Electrical Tests Rep air following Battery Voltage Indicated Trim switch is faulty or there is an open circuit in wires green white blue white between trim buttons and trim pump Check trim switch Check all trim harness connec tors for loose or corroded con nections Check for pinched or severed wires Battery Voltage Indicated There
123. outlet valve opens when primer bulb is squeezed to allow fuel flow to carbure tor but closes as bulb is released to prevent fuel from returning to primer bulb 3 20 FUEL SYSTEM AND CARBURETION c Fuel Line Clamp Removal and Installation 1 To remove fuel line clamps grip clamp with pliers and bend overlapping hook backward 51115 2 To install fuel line clamps grip hose clamp with pliers and push down on hook with screwdriver until hooks interlock 51115 90 814676R1 DECEMBER 1996 Carburetor Removal Manual Start Model NOTE Fuel pump can be removed from engine block to aid in carburetor removal 1 Remove 4 nuts securing carburetors to power head Disconnect fuel hose from fuel pump and primer hose 52022 Nuts Fuel Hose Fuel Pump Primer Hose 90 814676R1 DECEMBER 1996 Carburetor Disassembly Top Carburetor 1 Disconnect fuel hose and primer hose from car buretor a Fuel Hose b Primer Hose 52012 2 Disconnect throttle linkage from throttle shaft 52020 a Throttle Linkage b Throttle Shaft FUEL SYSTEM AND CARBURETION 3 21 5 Remove primer fitting bowl and bowl gasket from carburetor 3 Remove 4 screws securing cover plate to carbu retor 52012 a Screws a Primer Fitting b Cover Plate b Bowl c Gasket 4 Remove cover plate and gasket 52018 a Gasket 3 22 FUEL SYSTEM AND CA
124. pass through the shock piston As the fluid passes through the piston the piston rod a will ex tend from the trim cylinder The memory piston t is held in position by vacuum created by the oil in the up cavity being locked in a static position Therefore oil passing through the shock piston is trapped be tween the memory piston t and shock piston u 90 814676R1 DECEMBER 1996 MID SECTION 5E 15 _ SHOCK FUNCTION RETURN _ j Reservoir m n Zu Return Oil mil Oil Under Pressure lt p E Impact Relief Pressure 22 Tn gt 880 1110 40 60 AU 1220 1420 75 125 Up 1625 40 60 Tilt Relief 2800 75 125 250 400 40 60 540 990 75 125 a Piston Rod m Shuttle Valve b End Cap n Up Pressure Operated Valve Electric Motor o Manifold Reverse Suction Valve d Reservoir Oil p Manual Release Valve e Down Pressure Regulating Valve q Manifold f Down Pressure Operated Valve r Tilt Relief Valve g Filter 2 shown for clarity S Tilt Relief Piston h Shock Retur
125. proceed to TEST 8 No voltage reading check yellow cable for poor connection or open circuit TEST POINTS TEST 8 a Reconnect yellow starter motor cable to starter solenoid Test Point 1 b Connect voltmeter between common engine ground and Test Point 7 c Turn ignition key to Start position 12 Volt Reading If starter motor does not turn check that starter motor is grounded to powerhead If starter motor is grounded to powerhead check starter Battery Voltage Refer to preceding page for Test Point location 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2B 9 Starter Removal and Installation Removal Before working on outboard disconnect battery leads from battery and high tension leads from spark plugs 1 Disconnect battery leads form battery and high tension leads from spark plugs 2 Disconnect BLACK positive cable from starter motor 3 Remove two upper mounting bolts lockwashers and BLACK ground cable from upper starter mounting clamp Remove clamp 4 Remove two bottom mounting bolts lockwash ers BLACK ground cable and BLACK ground wire Remove lower mounting clamp 5 Lift starter motor from outboard 54652 Black Positive Cable b Upper Mounting Bolts c Black Ground Cable d Upper Mounting Clamp e Bottom Mounting Bolts f Black Ground Cable from Battery
126. ring from memory piston O ring b Memory Piston 7 Remove trim system from vise and empty fluid 51196 into appropriate container 5 Remove memory piston from cylinder using lock ring pliers shown or suitable tool Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check ball components from trim rod piston a Screw b Plate c O ring CAUTION 51193 When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to trim piston 90 814676R1 DECEMBER 1996 MID SECTION 5B 23 4 Placetrim rod into soft jawed vise and apply heat to shock piston using torch lamp P N 91 63209 5 Loosen trim rod piston using spanner wrench 1 4 in x 5 16 in long pegs 6 Allow trim rod piston to cool remove from trim 51146 a Trim Rod Piston b Spanner Wrench 5B 24 MID SECTION cM CAUTION Do not remove check ball components from trim rod piston Removal and reinstallation of check valve could result in improper operating pres sure and possible power trim system damage If check valve is defective replace trim rod piston 7 Remove inner O ring from piston 51199 Check Ball Components O ring Piston oom Remove rod wiper inner O ring and outer O ring 51145 a Rod Wiper b Inner O ring c Outer O ring 90 814676R1 DE
127. rod end must snap onto ball of tilt lock lever without moving tilt lock lever or cam lever 90 814676R1 DECEMBER 1996 MID SECTION 5G 35 i LOWER UNIT GEAR HOUSING Table of Contents Special Tools Quicksilver Lubricants and Service Aids Gear Housing Assembly Drive Shaft Components Torque Specifications Lubrication Sealant Application Points Gear Housing Assembly Propeller Shaft Components Torque Specifications Lubrication Sealant Application Points Draining and Inspecting Gear Housing EUbrICant ive se xr RE EE YE ead E Trim Tab Propeller Removal Gear Housing Removal Gear Housing Disassembly Water Pump Removal Bearing Carrier and Propeller Shaft Drive Shaft and Pinion Gear Lubrication Sleeve Removal Forward Gear and Bearing Removal Shift Shaft Drive Shaft Needle Bearing Cleaning and Inspection Gear Housing Bearing Carrier 5 Bearings 2s RR x RR ERR ERR Ball Roller Bearings Needle Bearing Propeller Shaft Forwa
128. to see if fuse is blown No Voltage Indicated Connect red Voltmeter lead to Point 5 and black lead to ground Fuse Not Blown Connect Voltmeter red lead to Point 3 and black lead to ground Battery voltage should be indi cated Battery Voltage Indicated Connect Voltmeter red lead to Point 8 and black lead to ground Depress Up trim button and check for battery voltage Battery Voltage Indicated Check black ground wires for poor connection or poor ground Pump motor is faulty Refer to Motor and Electrical Tests Rep following Battery Voltage Indicated Trim switch is faulty or there is an open circuit in wires green white blue white between trim buttons and trim pump Check trim switch Check all trim harness connec tors for loose or corroded con nections Check for pinched or wires Battery Voltage Indicated There is an open circuit in wire be tween Point 5 and Red terminal on the back of the ignition switch 90 814676R1 DECEMBER 1996 Q Power Trim System Removal Support outboard with tilt lock lever when servicing power trim system 1 Disconnect power trim harness form outboard wiring harness 2 Remove screw and clip securing wiring harness to clamp bracket 3 Use suitable tool to remove DRIVE DOWN up per dowel pin Retain pin S 51144 a Dowel Pin 4 Use suitable punch to drive ou
129. to 20 Ib ft 27 a Flat Washer 2 b Nylon Insert Locknut Torque Until It Seats DO NOT Ex ceed 120 Ib in 14 N m of Torque Then Back Nut Off 1 4 Turn Special Washer Head Bolt P N 10 14000 Torque to 20 Ib ft 27 1 N m d Nylon Insert Locknut Torque to 20 Ib ft 27 N m e Steering Link Rod After installation is complete and before operat ing outboard check that boat will turn to right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interference free movement OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 9 Steering Cable Installation Cable Routed Down Port Side of Boat to Starboard Outboard TILT TUBE REVERSAL CAUTION Outboard tilt tube MUST BE removed and rein stalled in the opposite direction turned end for end so that when reassembled longer threaded end of tilt tube extends out port side of outboard approximately 3 4 in 19mm Failure to reposi tion outboard tilt tube as described could inter fere with steering system operation Remove outboard tilt tube and reinstall in opposite direction turn end for end so that when reas sembled longer threaded end a of tilt tube extends out port side of outboard approximately 3 4 in 19mm Refer to Section Midsection 50579 Refer to Quicksilver Accessories Guide
130. to be OK Replace O rings Replace defective valve and O rings Inspect Memory Piston O ring Result Result O ring appear to be OK Cylinder O ring memory piston or cylinder bore and memory piston are OK bore defective Replace O rings and proceed Inspect Pump O rings located Replace defective O rings or below oil pump components Result Result O ring failure located below oil O rings appear to be OK Re pump place O rings Replace O rings Replace oil pump 5C 14 MID SECTION 90 814676R1 DECEMBER 1996 Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Inspect Manual Release Valve Result Result Manual release valve and O rings Manual release valve and or O ring damage appear to be OK Replace O rings and proceed Replace defective valve and O Inspect Trim Rod Piston Check rings Valve Result Result No debris or defective components Debris found in check valve com found ponents Inspect Manifold Reverse Thrust Clean check valve components Valve using engine cleaner and com pressed air or replace Result Result Debris found in manifold reverse No debris found in manifold re thrust valve components verse thrust valve Clean manifold reverse thrust Replace Manifold as a Unit valve without removing compo nents using engine or cleaner and compressed air or replace
131. to deter mine correct length of steering cable and remote con trol cables IMPORTANT Steering cable and remote control cables must be the correct length sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables Install steering mount and steering wheel in accor dance with installation instructions that accompany each 7 10 OUTBOARD MOTOR INSTALLATION ATTACHMENTS c Installing Steering Cable IMPORTANT Before installing steering cable into tilt tube lubricate entire cable end with Quicksilver 2 4 C Marine Lubricant NOTE Ride Guide Steering Cable is lubricated at the factory and requires no additional lubrication at initial installation 1 Lubricate inside of outboard tilt tube a and en tire steering cable end b with Quicksilver 2 4 C Marine Lubricant 2 Insert steering cable end thru outboard tilt tube and secure steering cable to tilttube with steering cable attaching nut c as shown Torque nutto 35 Ib ft 41 N m 50579 3 Place a mark a on tilt tube 1 4 in 6 4mm from starboard end of tube Slide plastic spacer b O ring c and cap d over steering cable end to tilt tube on outboard 50325 90 814676R1 DECEMBER 1996 c t Installing Steering Link Rod NOTE Steering link rod and components from Ride Guide Attaching Kit P N 17432A6 must be used when steering cable is r
132. to retaining tool and container A No 10 can or 3 Ib coffee can can be used 2 Fill container to near full level using Quicksilver Power Trim and Steering Fluid or ATF Type F FA or Dexron Il IMPORTANT Fluid level must remain above ac cumulator opening during bleeding process CREE EEECEECCCCHECETEUEEC ry 50447 Retaining Tool Tilt System Container Cam Lever Accumulator Opening 5F 34 MID SECTION f 3 Bleed unit by pushing rod down slowly 18 20 se conds per stroke until stopped at base Wait until all air bubbles exit accumulator base 4 During up stroke pull up on rod slowly 3 in 76mm from base 5 Wait until all air bubbles exit accumulator base 6 Slowly cycle unit 5 8 times round trip per cycle using short strokes 3 in 76mm from base allow ing bubbles to disappear during each stroke 90 814676R1 DECEMBER 1996 p i 7 Allow unit to stand five minutes then proceed to 11 With cam lever remaining open facing down re cycle unit 2 3 more times using short strokes No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise Torque accumulator to 35 Ib ft 47 at this time N m 8 With oil level well above accumulator port slowly pull rod to full up position 9 Install accumulator making sure air bubbles do not enter system Manual Tilt System Installation 1 Apply
133. to terminals and c Continuity Indicated Connect black meter lead to ground red lead alternately to terminals a and c No Continuity Indicated Connect black meter lead to ground red lead alternately to terminals a and No Continuity Indicated Connect black meter lead to terminal b red lead alternately to terminals and c Continuity Indicated Replace rectifier No Continuity Indicated Replace rectifier Continuity Indicated Connect black meter lead to terminal b red lead alternately to terminals and c Continuity Indicated Connect red meter lead to terminal b black lead alternately to terminals and c No Continuity Indicated Replace rectifier Continuity Indicated Replace rectifier No Continuity Indicated Connect red meter lead to terminal b black lead alternately to terminals and c No Continuity Indicated Rectifier tests O K Continuity Indicated Replace rectifier No Continuity Indicated Continuity Indicated Replace rectifier Rectifier tests O K 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2B 7 Starter System Starter System Components The starter system consis
134. up to 4000 RPM Using Test Harness 91 14443A1 allows performing DVA Tests from the driver seat inside the boat Refer to DVA Tests preceding 90 814676R1 DECEMBER 1996 Ignition Key Switch Test 1 Disconnect remote control wiring harness and in strument panel connector NOTE Wiring diagram for control boxes is located in SECTION 2D 2 Set ohmmeter on H x 1 scale for the following tests COMMANDER KEY SWITCH BLKe BLACK A PUP PURe PURPLE REDe RED M BLK BLK YEL M RED B 6 YEL REE CONTINUITY SHOULD INDICATED KEY AT THE FOLLOWING POINTS POSITION BLK BLK YEL RED YEL RED PUR YEL BLK Key switch must be positioned to RUN or START and key pushed in to actuate choke for this continuity test 3 meter readings are other than specified in the preceding test verify that switch and not wiring is faulty If wiring checks OK replace switch 90 814676R1 DECEMBER 1996 Mercury Tilt Stop Switch Test 1 Remove mounting screw that secures mercury switch to outboard N Connect Ohmmeter R x 1 scale between black lead and black yellow lead or terminal stud on mercury switch 3 Test mercury switch as follows a Position mercury switch as it would be installed when engine is in down position The meter should indicate no continuity b Tilt mercury switch up The meter should indi cate continuity c If these readings are not obtain
135. valve to car buretors for leaks or obstructions No Fuel Flow from Fitting Remove upper hose from fitting on enrichener valve If fuel flows from hose replace valve If not check hose and carbu retor fittings for leaks or obstructions Enrichener Valve 4 Reinstall hoses to valve Refer to Hose Installa R tion following eplacement 5 Apply a drop of Loctite 271 92 32609 1 to 1 Disconnect enrichener valve leads at bullet con nectors Disconnect hoses from valve Remove bolt that secures valve mounting brack et to engine then lift from engine 90 814676R1 DECEMBER 1996 threads of mounting bracket retaining bolt then secure valve to engine with bracket and bolt Connect enrichener valves leads at bullet con nectors FUEL SYSTEM AND CARBURETION 3 19 Fuel Line and Primer Bulb Assembly 50165 Fitting Clamp Fuel Line Primer Bulb Check Valve BLACK Check Valve WHITE Fuel Line Connector Engine End Periodically check fuel line and primer bulb for cracks breaks restrictions or chafing Check all fuel line connections for tightness All fuel line connec tions must be clamped securely Primer bulb assembly has 2 check valves Fuel inlet toward tank and a fuel outlet toward engine The fuel inlet valve allows fuel to fill primer bulb but closes to prevent fuel from returning to tank when bulb is squeezed The fuel
136. 0 814676R1 DECEMBER 1996 No debris found in valve block passages Replace defective valve block Manual Tilt System Removal CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard Service or installation of the tilt system may re sult in loss of pressure in the shock cylinder If the outboard is notin the full down position such loss of pressure will cause the engine to fall to the full down position with a potential for damag ing engine or causing personal injury To avoid such injury support outboard in the up position using tilt lock lever Manual tilt system is pressurized Accumulator must be removed when shock rod is in the full up position prior to servicing otherwise oil spray back may occur 1 Support outboard in the up position using tilt lock lever 2 Remove link rod 51143 a Link Rod b Accumulator 90 814676R1 DECEMBER 1996 3 Use suitable punch to remove DRIVE DOWN upper dowel pin Retain dowel pin Dowel Pin 4 Use suitable punch to drive out upper pivot pin 51144 a Pivot Pin 5 Use punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a Dowel Pin MID SECTION 5F 21 6 Use suitable punch to drive out lower pivot pin 51144 a Pivot Pin 7 Tilt shock absorber assembly TOP FIRST out from clamp bracket and remove assembly
137. 1 MANUAL TILT COMPONENTS B 7 Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all O rings be replaced when servicing tilt system 5G 2 MID SECTION 90 814676R1 DECEMBER 1996 MANUAL TILT COMPONENTS TORQUE QTY DESCRIPTION Ib in Ib ft MANUAL TRIM ASSEMBLY MANUAL TRIM BEACHING ASSEMBLY SHOCK ROD ASSEMBLY SHOCK ROD ASSEMBLY BEACHING MEMORY PISTON ASSEMBLY O RING REBUILD KIT Cylinder O RING CYLINDER ASSEMBLY SCREW AND SEAL KIT ACCUMULATOR ASSEMBLY VALVE BODY ASSEMBLY CAM KIT VELOCITY VALVE KIT CHECK SYSTEM REPAIR KIT O RING KIT PIN GROOVE PIN A Torque cylinder cap to 45 Ib ft 61 B Torque Accumulator to 35 Ib ft 47 N m C Torque Velocity Valve to 75 Ib in 8 5 N m D Torque Transfer Valve Plug to 75 Ib in 8 5 N m E Torque Screw to 100 Ib in 11 Torque Shock Piston to 90 Ib ft 122 N m 2 3 4 5 6 7 8 9 o N DYN a 90 814676R1 DECEMBER 1996 MID SECTION 5G 3 MANUAL TRIM FLOW DIAGRAMS a Shock Rod b End Cap Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Man
138. 10 40 60 1220 1420 75 125 AU x wey c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port Oil Pump k Down Circuit Suction Port Oil Fill Cap 5E 12 MID SECTION Tit Relief assure 250 400 40 60 q 540 990 75 125 m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Relief Valve s Tilt Relief Piston t Memory Piston u Shock Piston v Impact Relief Valve w Oylinder 90 814676R1 DECEMBER 1996 Down Mode When the trim switch is activated in the down posi tion the electric motor c will rotate the pump j in the opposite direction With the pump gears rotating backwards the flow of oil is reversed Oil is drawn through the filter 9 through the down circuit suction port k and into the oil pump j The pump forces pressurized oil into the down passages oil will slide the shuttle valve m into the up circuit pressure oper ated valve n The shuttle valve will mechanically open the up circuit pressure operated valve and allow oil from the up cavity of the trim cylinder w to return into the oil pump This returning oil from the up cav ity will supply the oil required for the down circuit The oil is blocked from returning in
139. 2 Install valve block to shock rod cylinder Torque screws to 100 Ib in 11 2 51146 a Screw 2 b Valve Block c Shock Rod Cylinder 5F 30 MID SECTION 3 Install lubricated O ring 51145 Shock Rod Reassembly 1 Install lubricated O rings 2 Install rod wiper Q S 7 amp 51145 a Rod Wiper b Inner O ring C Outer O ring 90 814676R1 DECEMBER 1996 p 1 3 Install lubricated O ring 51199 O ring Shock Piston A Clamp shock rod in soft jawed vise 5 Position cylinder end cap onto rod as shown 51146 CAUTION When installing shock rod piston spanner wrench must have1 4 in x 5 16 in 6 4mm x8mm long pegs to avoid damage to shock rod piston 6 Apply Loctite Grade A 271 to threads on shock rod 7 Install shock rod piston 90 814676R1 DECEMBER 1996 8 Tighten shock rod piston securely using spanner wrench 1 4 in x 5 16 in long pegs 51146 a Shock Rod Piston b Spanner Wrench 9 Remove shock rod assembly from vise 10 Install lubricated O ring to shock rod piston 11 Install ball seat and spring five sets to shock rod piston 12 Secure components with plate Torque screws to 35 Ib in 4 0 51147 Screw 3 Plate O ring Ball 5 Seat 5 Spring 5 0 8 MID SECTION 5F 31 Shock Rod Installation 6 Refill cylinder to top 1 Place cylind
140. 2 volts while crank ing the battery is weak and should be recharged or replaced Winter Storage of Batteries Battery companies are not responsible for battery damage either in winter storage or in dealer stock if the following instructions are not observed 1 Remove battery from its installation as soon as possible and remove all grease sulfate and dirt from top surface by running water over top of bat tery Be sure however that vent caps are tight beforehand and blow off all excess water thor oughly with compressed air Check water level making sure that plates are covered 2 When adding distilled water to battery be ex tremely careful notto fill more than 3 16 4 8mm over plate inside battery Battery solution or elec trolyte expands from heat caused by charging Overfilling battery will cause electrolyte to over flow if filled beyond 3 16 over plate 3 Grease terminal bolts well with Quicksilver 2 4 C Multi Lube and store battery COOL DRY place Remove battery from storage every 30 45 days check water level add water if necessary and put on charge for 5 or 6 hours at 6 amperes DO NOT FAST CHARGE 4 lf specific gravity drops below 1 240 check bat tery for reason and recharge When gravity reaches 1 260 discontinue charging To check specific gravity use a hydrometer which can be purchased locally 5 Repeat preceding charging procedure every 30 45 days as long as battery is in storage for
141. 3 as shown Both special washer head bolt and nylon insert locknuts MUST BE tight ened as specified Lubricate hole in end of steering cable with Quicksil ver 2 4 C Marine Lubricant Assemble steering link rod to steering cable end using 2 flat washers and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 14 N m of torque then back nut off 1 4 turn 90 814676R1 DECEMBER 1996 Lubricate ball joint in steering link rod with SAE 30W Motor Oil Secure link rod to outboard steering arm using special washer head bolt P N 10 14000 pro vided and nylon insert locknut as shown Torque spe cial bolt 20 Ib ft 27 then torque locknut to 20 Ib ft 27 N m 50056 50182 a Flat Washer 2 b Nylon Insert Locknut Torque Until It Seats DO NOT Ex ceed 120 Ib in 14 of Torque Then Back Nut Off 1 4 Turn Special Washer Head Bolt P N 10 14000 Torque to 20 Ib ft 27 1 N m Nylon Insert Locknut Torque to 20 Ib ft 27 Steering Link Rod After installation is complete and before operat ing outboard check that boat will turn to right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interference free movement OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 5 19609A 2 Ride Guide Steering Attaching Kit Installation
142. 3 Increases clearance over submerged objects In excess can cause porpoising and or ventila tion 5 If trimmed out beyond the water pickup reduced water supply can cause serious overheating Trimming Outboard In Down Characteristics TH Excessive speed at minimum trim cause undesirable and or unsafe steering condi tions Each boat should be tested for handling characteristics after any adjustment is made to the trim angle trim adjustment pin relocation 1 Will help planing off particularly with a heavy load 2 Usually improves ride in choppy water IMPORTANT INFORMATION 1 5 3 excess can cause boat to veer to the left or right bow steer 4 Transfers steering torque harder to right or less to the left on single outboard installations 5 Improves planing speed acceleration Trim Tab Adjustment 1 Check trim tab position as follows a Operate boat at the speed at which it would normally be operated b If the boat pulls to the right starboard the trailing edge of trim tab must be moved to the right If the boat pulls to the left port the trail ing edge of trim tab must be moved to the left 2 If necessary adjust trim tab as follows a Shift outboard control into neutral and turn ignition key to Off position b Remove plug from rear of drive shaft housing and loosen bolt and trim tab If boat pulls to the left adjust trailing edge of tr
143. 3 Vent Screw 34 Fill Screw 35 Gasket 2 36 Lubrication Sleeve 37 Shim s 38 Tapered Bearing 39 Drive Shaft 40 Spring 41 Pin 42 Shift Shaft 43 E Clip 44 O ring 45 Bushing 46 Oil Seal OANDARWD Torque Specifications Q 50 lb ft 67 8 N m 17 Ib ft 23 N m 60 lb in 6 8 N m 30 lb in 3 4 N m 50506 6A 2 LOWER UNIT 90 814676R1 DECEMBER 1996 p DE Gear Housing Assembly Propeller Shaft Components Gear Housing Shift Cam Number Side Toward Top of Gear Case Shim s Bearing and Race Forward Gear Needle Bearing Cam Follower Guide Block Spring 10 Sliding Clutch 11 Cross Pin 12 Spring 13 Propeller Shaft 14 Reverse Gear 15 Thrust Washer 16 Ball Bearing 17 O ring 18 Bearing Carrier 19 Needle Bearing 20 Oil Seal 21 Oil Seal 22 Alignment Key 23 Tab Washer 24 Cover Nut 25 Trim Tab 26 Bolt 27 Washer 28 Locknut 29 Washer 30 Locknut 31 Thrust Hub 32 Locking Washer gt 90 814676R1 DECEMBER 1996 Torque Specifications Q 100 Ib ft 135 6 N m 60 Ib ft 81 4 N m 55 Ib ft 74 6 N m 20 Ib ft 27 1 N m Lubrication Sealant Application Points 2 4 C Marine Lubricant P N 92 90018 12 Special Lubricant 101 P N 92 13872A1 C C Needle Bearing Assembly Lubricant P N 92 42649A 1 Quicksilver Gear Lubricant P N 92 13783A24 B
144. 301 in 1 0 39 Cam Shaft 40 Insulator 41 Retainer Plate 42 Screw 43 O ring 2 114 in I D 44 Push Rod 45 Ball 46 Flat Spring 47 Screw VN Quicksilver Lubricant Sealant Application Points Lubricate ALL O rings using Quicksilver Power Trim and Steering Fluid or ATF FA or Dexron Il Loctite Grade A 271 Loctite Pipe Sealant with Teflon 592 Special Lubricant 101 NOTE It is recommended that ALL O rings be re placed when servicing tilt system 5F 2 MID SECTION 90 814676R1 DECEMBER 1996 Q Manual Tilt Flow Diagrams Design 1 TILT UP RETURN OIL GAS PRESSURE 300 700 P S I 51651 90 814676R1 DECEMBER 1996 MID SECTION 5F 3 Design 1 TILT DOWN 234 OIL UNDER PRESSURE E RETURN OIL GAS PRESSURE 300 700 P S I 5F 4 MID SECTION 90 814676R1 DECEMBER 1996 Q Design 1 SLOW TILT DOWN UNDER HIGH THRUST 7 OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 51653 90 814676R1 DECEMBER 1996 MID SECTION 5F 5 EY Design 1 UNDER WATER STRIKE VALVES OPEN 5F 6 MID SECTION 90 814676R1 DECEMBER 1996 Q Design 1 SHOCK FUNCTION VALVES CLOSED OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 90 814676R1 DECEMBER 1996 MID SECTION 5F 7 Manual Tilt Flow Diagrams Design 2 TILT UP OIL UNDER PRESSURE RETUR
145. 4 90 814676R1 DECEMBER 1996 4 Remove motor harness from reservoir 51196 Trim Motor Disassembly 1 Remove end cap from motor housing Note posi tion of washers on armature End Cap Motor Housing Wave Washer 2 Washer MID SECTION 56 25 2 Remove O ring from end frame 3 Place scribe mark on motor housing and end frame as re assembly reference as shown 51194 a O ring b Scribe Mark 4 Remove end frame and armature from housing 51194 End Frame Washer Armature Fiber Guard Liner Housing 5 26 MID SECTION c i Reservoir Assembly Removal CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Remove manual release valve form manifold DO NOT remove or adjust reverse thrust valve 51194 a Manual Release Valve b Manifold 2 Remove E clip and O rings from manual re lease valve a E Clip b O rings c Manual Release Valve 90 814676R1 DECEMBER 1996 p i 3 Remove four screws securing reservoir to man Oil Pump Manifold Removal ifold 1 Remove screw oil pump O rings and check valve components from manifold 51193 a Screws 4 4 Remove reservoir from manifold a 5 Remove drive shaft from oil pump 51007 a O rings 3 b Oil Pump Screw d Spring e
146. 50 STATOR TEST RED STATOR Electric Start Engines 9 Amp Stator Ohm Test Leads To ESSE Reading YEL and YEL 4 1 0 Electric Start Engines 16 Amp Stator Ohm Test Leads To Reading YEL and YEL 0 165 0 181 Manual Start Engines Ohm Test Leads To Ew Reading YEL and YEL 0 17 0 19 90 814676R1 DECEMBER 1996 cM n Voltage Regulator Test LAMPS BURN OUT WHEN ENGINE IS REVVED UP The voltage regulator is defective Replace voltage regulator LAMPS BURN DIM AT WIDE OPEN THROTTLE Run outboard at midrange approximately 3000 RPM with 3 number 94 lamps connected to voltage regulator output leads Note lamp brightness Disconnect the leads at tone terminal of regulator Connect the leads together using a screw and nut Isolate tape connection Run outboard at midrange approximately 3000 RPM and note lamp brightness If lamps are consid erably brighter than with leads connected to regula tor the regulator is defective If lamps are NOT con siderably brighter check the alternator refer to Stator Test previously Alternator System Test MANUAL START MODELS STATOR OUTPUT TEST The stator that comes with manual start models is NOT designed to produce its rated amperage at low engine speeds to charge batteries but rather as a power source for running lights However if a rectifier kit is installed on the engine to enable the stator to charge a battery the following approximate output be che
147. 5B 29 Motor Disassembled 5B 29 Armature Tests 5B 30 Test for Shorts 5B 30 Test for Ground 5B 30 Checking and Cleaning Commutator 5B 30 Power Trim System Reassembly 5B 30 Manifold Installation 5B 30 Oil Pump Installation 5B 31 Trim Motor Reassembly 5B 32 Reservoir Installation 5B 33 Trim Rod Re assembly 5B 35 Trim Rod Installation 5B 36 Bleeding Power Trim Unit 5B 37 Power Trim Unit Installation 5B 37 90 814676R1 DECEMBER 1996 p e Power Trim General Information Description The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The remote control or trim panel is equipped with a switch that is usedfortrimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running Trimming Characteristics NOTE Because varying hull designs react differently in various degrees of rough water it is recommended to experiment with trim positions to determine wheth er trimming up or down will improve the ride in rough water When trimming your outboard from a mid trim posi tion tr
148. 6 Amp Black Stator BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT BLU LIGHT BLUE Stator Trigger Switch Box Voltage Regulator Starter Starter Solenoid Battery To Bottom Cowl To Tan Female Connector on Remote Control Harness Plug 10 Temperature Gauge Sender OANDOARWND 2D 8 ELECTRICAL AND IGNITION 52467 11 Warning Module 12 Overheat Switch 13 Low Oil Sensor 14 Coil No 1 15 Coil No 2 16 Coil No 3 17 Coil No 4 18 20 Ampere Fuse 19 Fuel Enrichment Valve 20 Neutral Start Switch 21 Emergency Stop Switch 90 814676R1 DECEMBER 1996 c Wiring Diagram Model 40 Electric Start Tiller Handle with 16 Amp Red Stator BLK BLU BRN GRY GRN ORN PNK PUR RED Tan WHT YEL 90 814676 1 Brown Gray Green Orange Pink Purple Red Tan White Yellow Light Dark K BLK Y EL BLI 2 16 Stator Stator Adaptor Voltage Regulator Switch Box Ground Connection 54945 DECEMBER 1996 ELECTRICAL AND IGNITION 2D 9 c Wiring Diagram Model 40 Manual Start with Black Stator BLK Black BLU Blue BRN Brown GRY Gray GRN Green TRIGGER ORN Orange PUR Purple RED Red WEE Wills TERMINAL BLOCK YEL Yellow LIT Light DRK Dark
149. 676R1 DECEMBER 1996 4 Placetrim rod into soft jawed vise and apply heat to shock piston using torch lamp a P N CAUTION 91 63209 Do not remove check ball components a from trim rod piston Removal and re installation of check valve could result in improper operating pressure and possible power trim system dam 6 iu trim rod piston to cool Remove from trim age If check valve is defective replace trim rod rod piston 5 Loosen trim rod piston using spanner wrench 1 4 in x 5 16 in long pegs 7 Remove inner O ring from piston 51199 a Check Ball Components b O ring c Piston 8 Remove rod wiper inner O ring and outer O ring 51146 51147 51145 a Rod Wiper 51146 b Inner O Ring b Spanner Wrench Outer O Ring c Trim Rod Piston 90 814676R1 DECEMBER 1996 MID SECTION 5D 17 Trim Motor Removal Trim Motor Disassembly 1 Secure power trim assembly in soft jawed vise 1 Remove armature from motor frame Note posi 2 Remove screws securing end cap to reservoir tion of washers on armature and remove end cap Armature Motor Frame Washer 1 each end of armature oo Reservoir Assembly Removal 1 Remove manual release valve from manifold a Screws 4 3 Remove motor from reservoir p C ZA a Manual Release Valve b Manifold 2 Remove E clip and O rings from manual re lease valve 51484 a E Clip b O rings c Manual
150. 76R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 1 Fuel System Carburetor Carburetor Body Welch Plug Plug Throttle Shutter Spring Baffle Float Pivot Pin Fuel Bowl 10 Gasket 11 Gasket 12 Needle 13 Main Jet 14 Vent Jet 15 Venturi 16 Screw 2 17 Gasket 18 Idle Mixture Screw 19 Spring 20 Gasket 21 Screw 4 22 Throttle Shaft 23 Nut 2 Upper Carburetor 24 Cover Plate 25 Throttle Lever 26 Fitting 27 Main Jet WMA9 Carburetor 28 Cover Plate 29 Screw 30 Throttle Lever 31 Screw 32 Screw 33 Main Jet WMA9 Quicksilver Lubrication Sealant Application Points Loctite 271 92 32609 1 3 2 FUEL SYSTEM AND CARBURETION Torque Specifications 110 Ib in 12 1 33 Ib in 3 7 N m 18 Ib in 2 0 N m 14 Ib in 1 6 6 Ib in 07 90 814676R1 DECEMBER 1996 p 1 Fuel System Fuel Pump gt 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Rubber Disk 2 Plastic Disc 2 Retainer 2 Spring Cap Diaphragm Gasket Spring Cap Plate Gasket Gasket Pump Base Gasket Bolt 40 mm 2 Bolt 50 mm 2 Pipe Plug Pipe Plug Hose Fuel Connector Bolt 1 1 2 in Nut Hose Filter Hose Hose 2 Tee Fitting Balance Tube Sta Stra
151. 814676R1 DECEMBER 1996 MID SECTION 5G 11 Shock Rod b End Cap Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 12 MID SECTION Shock Function Valve Clos Gas Pressure 400 PSI Accumulator ed Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston Shock Return Valve p Impact Relief Valve 90 814676R1 DECEMBER 1996 Shock Function With Valves Closed Should the drive unit strike a submerged object while in forward motion the shock rod a will extend from the cylinder Oil inside the up cavity is locked in a static position by the closed up fast transfer valve j the closed down slow transfer valve i and closed down fast transfer valve h Fluid will attempt to exit the cylinder through the interconnecting passage back into the accumulator c The closed up fast transfer valve j will prevent the fluid return As the shock rod extends outward the pressure inside the up cavity will reach sufficient pressure to open the shock valve p which opens at 880 1110 psi will flow into the cavity created as the shock rod amp shock piston a amp n moves away from the memory piston m 90 814676R1 DECEMBER 1996 MID SECTION 5G 13 Shock Rod b End Cap Accumulator d Accumulator Pisto
152. 92 25711 1 D 35 lb in 4 0 Power Trim and Steering Fluid 92 90100A12 90 814676R1 DECEMBER 1996 MID SECTION 5D 3 Troubleshooting Determining if Problem is Electrical or Hydraulic When a problem is encountered with the Power Trim system the first step is to determine whether the mal function is in the electrical system or the hydraulic system Refer to the following chart to determine which system is at fault Problem Chart Outboard will not trim up or down Determine if Power Trim Outboard trims up will not trim pump motor operates when down appropriate trim circuit is activated Outboard trims down will not trim up Outboard will not return com pletely to down position or re Pump motor docsnotoperalg turns part way with jerky mo tion Outboard thumps when shifted Refer to Hydraulic System Refer to Electrical System Troubleshooting Troubleshooting Outboard trails out when back ing off throttle at high speed Outboard will not hold a trimmed position or will not re main tilted for any extended period Outboard will not hold trim po sition when in reverse 5D 4 MID SECTION 90 814676R1 DECEMBER 1996 c iy Hydraulic System Troubleshooting Support outboard with tilt lock lever when servicing power trim system After debris or failed components have been found during troubleshooting procedures dis
153. 95 Reservoir Installation a End Cap b O ring 1 Connect trim motor wires to harness c Foam Pad 2 Insert motor into reservoir Motor must be seated properly prior to end cap installation 5 Install grommet washer and screw cap to cylin der end cap Tighten screw securely 51195 a Grommet b Washer Screw 90 814676R1 DECEMBER 1996 MID SECTION 5B 33 Place drive shaft into oil pump Install lubricated O ring to base of reservoir Carefully guide reservoir with motor down onto drive shaft a Drive Shaft b O ring 9 Secure reservoir to manifold using four screws Torque screws to 70 Ib in 7 9 51193 5B 34 MID SECTION 10 Install lubricated O rings clip to manual release valve a E b O ring c Manual Release Valve 11 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 or 4 turns allowing trim rod installation a Manual Release Valve b Manifold c Reverse Thrust Valve 90 814676R1 DECEMBER 1996 c Trim Rod Reassembly 1 Install lubricated O rings and rod wiper to end cap e 51145 a Rod Wiper b Inner O ring C Outer O ring 2 Secure trim rod in soft jawed vise as shown 3 Slide end cap onto trim rod 51146 a End Cap 90 814676 1 DECEMBER 1996 4 Apply Loctite Grade A 271 to threads of trim rod and install trim rod p
154. ATF automatic transmission fluid 4 Install shock rod into cylinder until power trim fluid flows through oil blow off ball passage Fill re maining cylinder to just below the cylinder threads a Blow Off Ball Passage CAUTION End cap must not make contact with shock rod piston when tightening Shock rod piston must be positioned in cylinder deep enough to avoid contact 5 Tighten end cap securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner tool is used to tighten end cap then torque to 45 Ib ft 61 0 MID SECTION 5E 39 Trim Limit Assembly Installation 1 Lubricate all O rings Install spring poppet spool housing and trim limit spool into manifold NOTE There are two different size springs used in this manifold The heavy spring is used on 75 to 125 HP engines The light spring is used on 40 to 60 HP engines orm o B d 5 006 Spring Poppet Spool Housing Trim Limit Spool Manual Release Valve Installation 1 Install E clip if removed and lubricate O rings to manual release valve 2 Install manual release valve assembly into man ifold a Manifold b Manual Release Valve c Clip 5E 40 MID SECTION cM 1 Install dowel pin and two 2 lubricated O rings into trim cylinder Manifold Installation a O Rings 2 b Dowel Pin 2 Align the trim cylinde
155. Aids 20 O ring 208 in I D 2 2 en H A Loctite Grade A 271 O ring 1 0 23 Valve Seat 2 4 C Marine Lubricant 92 90018A12 24 O ring 364 in I D 25 Ball 26 Spring Guide 27 Spring 28 Dowel Pin 2 29 Reservoir 30 Fill Screw 31 O ring 583 in I D 32 Screw 4 33 Washer 4 34 O ring 2 364 I D 35 Screw 36 Drive Shaft 37 Pump 38 O ring 176 in 1 0 2 39 Dowel Pin 40 Manifold 41 O ring 114 1 0 42 O ring 208 I D 43 O ring 239 in I D 44 Relief Valve 45 E Clip 46 Wire Harness 47 Cap 48 Washer 49 Grommet 50 Screw 4 51 Screw 52 Reservoir Cap 53 O ring 2 364 I D 54 Disk Foam Pad 55 Nut 2 56 End Cap 57 Washer 030 in Thick 2 58 Washer Thrust 59 Armature 60 Washer 010 in Thick 61 Housing 62 O ring 63 End Frame 64 O ring 489 I D 65 Screw 2 in 26153 90 814676R1 DECEMBER 1996 MID SECTION 5B 3 Power Flow Diagrams Design 1 EB TRIM UP qu _ 1 RESERVOIR AND FEED OIL 52 OIL UNDER PRESSURE RETURN OIL 599 OS 51638 5B 4 MID SECTION 90 814676R1 DECEMBER 1996 90 814676 1 DECEMBER 1996 TRIM DOWN O RESERVOIR AND FEED OIL OIL UNDER PRESSURE RETURN OIL 51637 MID
156. Apply 2 4 C Marine Lubricant to lips of oil seals a Block b Arbor Press PR IMPORTANT If installing a Design 1 2 or 3 end a O Ring Seal cap on engine S N 0D040454 and below remove b Mandrel and discard seal if equipped from end of drive Design 1 End Cap shaft a 26 41953 Oil Seal 2 Design 2 End Cap 51188 a Seal a 26 41953 Oil Seal 1 b 26 63742 Oil Seal 1 Design 3 End Cap a 26 41953 Oil Seal 2 4 38 POWERHEAD 90 814676R1 DECEMBER 1996 1 Ifremoved press ball bearing into upper end with press block 54720 a Block b Arbor Press 2 Apply Loctite Grade A 271 to outer diameter on oil seal and press into end cap with lip of seal toward ball bearing using proper mandrel Re move excess Loctite from end cap 54721 a Oil Seal Lip Toward Ball Bearing 90 814676R1 DECEMBER 1996 Cylinder Block Reassembly 1 Lubricate piston rings pistons and cylinder walls with light oil 2 Rotate and align end of each piston ring with lo cating pin in ring groove CAUTION Piston rings MUST BE properly positioned with locating pin between piston ring end gaps Im properly positioned piston rings may break dur ing installation a Piston Ring Locating Pin 3 Install ring compressors as follows a No 1 piston must be straight out from crank pin throw
157. B 15 Jet Drive Tiller Handle Adaptor Klt 6B 16 Installation Instructions 6B 16 90 814676R1 DECEMBER 1996 Notes 90 814676R1 DECEMBER 1996 LOWER UNIT 6B 1 Jet Pump Assembly 000 95 D 2 4 With Teflon 92 825407 12 90 814676R1 DECEMBER 1996 6B 2 LOWER UNIT Jet Pump Assembly TORQUE DESCRIPTION Ib in Ib ft HOUSING pump HOSE lube IMPELLER HOUSING intake LINER SHAFT drive NUT SLEEVE shaft KEY SHIM TAB WASHER SCREW 1 4 20 x 75 SCREW 1 4 20 x 875 SCREW 1 4 20 x 625 SCREW 312 18 x 1 25 BRACKET NUT STUD PIN dowel RING SUPPORT water pump GASKET water pump base STUD 1 4 x 2 5 8 SCREW 3 8 16 x 3 WASHER WASHER NUT On By N Pol OU ma Po Po ma mA A BR GO mA Co may a Ss Ss ss sot 90 814676R1 DECEMBER 1996 LOWER UNIT 6B 3 cM Selecting A Boat That Is Best Engine Horsepower Suited For Jet Power Selection To obtain the best performance from the jet drive the A boat operating at slow speed requires considerably boat should have the following features more depth than one which is planing on the surface of the water It is important therefore to use sufficient horsepower and not to overload your boat beyond its 2 The boat shoul
158. CEMBER 1996 Trim Motor Removal 1 Secure power trim assembly in soft jawed vise 2 Remove cap washer and grommet from reser voir assembly 51195 Cap Washer Grommet 3 Remove screws securing reservoir cap to reser voir 51193 a Screws 90 814676R1 DECEMBER 1996 4 Remove motor and harness from reservoir 51196 Trim Motor Disassembly 1 Remove end cap from motor housing Note posi tion of washers on armature End Cap Motor Housing Wave Washer 2 Washer MID SECTION 5B 25 2 Remove O ring from end frame 3 Place scribe mark on motor housing and end frame as reassembly reference as shown 51194 a O ring b Scribe Mark 4 Remove end frame and armature from housing 51194 End Frame Washer Armature Fiber Guard Brush Wires Housing 5B 26 MID SECTION Reservoir Assembly Removal CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Remove manual release valve from manifold DO NOT remove or adjust reverse thrust valve 51194 a Manual Release Valve b Manifold c Reverse Thrust Valve 2 Remove E clip and O rings from manual re lease valve a E Clip b O rings c Manual Release Valve 90 814676R1 DECEMBER 1996 Q 3 Remove
159. D IGNITION Positive Brushes Installed 11660 a Positive Terminal b Long Brush Lead c Push Lead into Slot b Install negative brushes along with brush holder Negative Brushes Installed a Positive Brushes b Negative Brushes c Brush Holder d Bolts Fasten Negative Brushes and Holder 90 814676R1 DECEMBER 1996 1 removed reinstall parts on armature shaft Use a new locknut and tighten securely on end of shaft Lubricate helix threads on armature shaft with a drop of SAE 10W oil Lubricate bushing in drive end plate with a drop of SAE 10W oil Position armature into start frame so that com mutator end of armature is at end of starter frame where permanent magnets are recessed 1 25 4mm Lubricate bushing located in commutator end cap with one drop of SAE 10W oil DO NOT over lubricate To prevent damage to brushes and springs when installing commutator end cap it is recom mended that a brush retaining tool be made Brush Retainer Tool Dimensions 90 Bend Brush Retaining Tool Layout Full Size Y 18 Gauge Sheet Metal METRIC SCALE 3 76 2mm 2 50 8mm 1 3 4 445mm 1 11 16 42 9mm 3 4 19 1mm 1 2 12 7 Side View Full Size 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2B 15 8 Place springs and brushes into brush holder and hold in place with brush retainer tool 11661 a Brus
160. DECEMBER 1996 Operating Outboard without Battery If desired or in an emergency outboards equipped with an alternator can be started and operated with out a battery either disconnected or removed if Warning below is followed Before operating outboards with battery leads disconnected from battery the leads MUST BE taped off insulated or positioned in a manner that prevents a completed circuit between the leads Electric wiring harness MUST REMAIN CONNECTED to electric starting models in order to Stop the outboard with the ignition key Specific Gravity Readings Use ahydrometer to measure specific gravity of elec trolyte in each cell 22532 Hydrometer measures percentage of suplhuric acid in battery electrolyte in terms of specific gravity As a battery drops from a charged to a discharged condi tion acid leaves the solution and enters the plates causing a decrease in specific gravity of electrolyte An indication of concentration of electrolyte is ob tained with a hydrometer ELECTRICAL AND IGNITION 2B 1 When using hydrometer observe the following points 1 Hydrometer must be clean inside and out to in sure an accurate reading 2 Nevertake hydrometer readings immediately af ter water has been added Water must be thor oughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause vigorous gassing 3 hydrometer has built in thermometer draw
161. DECEMBER 1996 Q Valve Block Disassembly 1 Remove slow trim valve assembly 2 Remove hydraulic oil transfer valve components 51143 a Transfer Valves 2 b Slow trim Valve Assembly Plug or Screw Plug 3 Remove surge valve assembly 51145 a Surge Valve 90 814676R1 DECEMBER 1996 4 Remove reservoir assembly 51142 a Screw b Flat Spring c Ball 5 Remove cam assembly 51145 a Screw b Cam Assembly MID SECTION 5F 27 Manual Tilt System Cleaning and Inspection 1 is recommended that all O rings exposed dur ing disassembly be replaced 2 Clean components filter and check valve seats using engine cleaner and compressed air Do not use cloth rags 3 Inspectall machined surfaces for burrs or scoring to assure O ring longevity 4 Inspect shock rod If wiper located cap has failed to keep rod clean replace wiper Manual Tilt System Reassembly IMPORTANT Components must be dirt and lint free Slightest amount of debris in tilt system could cause system to malfunction Apply Quicksilver Power Trim and Steering Fluid or ATF FA or Dexron II on all O rings during reassembly NOTE Refer to Manual Tilt System Components for proper O ring sizes Valve Block Reassembly IMPORTANT Cam shaft O ring must be cated using Special Lubricant 101 prior to instal lation 1 Install lubricated O ring to cam shaft 2 Install cam shaft in va
162. DRIVE DOWN upper dowel pin Retain dowel pin a Dowel Pin b Wood 4 Position tilt lock and remove piece of wood Use suitable punch to drive out upper pivot pin 51144 a Pivot Pin b Tilt Lock 5 Use punch to remove DRIVE UP lower dowel pin Retain dowel pin 51144 a Dowel Pin MID SECTION 5G 17 6 Use suitable punch to drive out lower pivot pin 51144 a Pivot Pin 7 Tilt shock absorber assembly TOP FIRST out from clamp bracket and remove assembly 51144 a Manual Tilt System 5G 18 MID SECTION Manual Tilt System Disassembly NOTE Accumulator contains a high pressure nitro gen charge and is NOT SERVICEABLE Replace if necessary This tilt system is pressurized Remove accumu lator only when shock rod is in full up position Accumulator Removal Place manual tilt system in soft jawed vise Position shock rod to full up position Open cam shaft valve Down Position Bp Loosen surge valve enough to drip wait until dripping stops 5 When fluid stops dripping loosen and remove accumulator a Accumulator 51143 b Cam Lever Velocity Plug 90 814676R1 DECEMBER 1996 6 If plunger be compressed into accumulator by hand accumulator is defective Replace accu mulator 51143 a Plunger 7 Once accumulator is removed remove O ring conical spring steel ball and plunger 51145 a Conical Spring b S
163. Disconnect all leads from switch box 4 Remove 4 bolts from switch box and remove switch box CUN i a Bolts b Switch Box 2 24 ELECTRICAL AND IGNITION cM Switch Box Installation 1 Secure switch box to electrical component box with 4 bolts and their respective ground leads Torque bolts to 40 Ib in 4 5 N m Reconnect leads to switch box terminals Refer to WIRING DIAGRAM SECTION 2D Torque switch box terminal nuts to 30 Ib in 3 4 N m Reinstall electrical box access cover and secure cover with 6 bolts Reinstall top cowl 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION BATTERY CHARGING SYSTEM and STARTING SYSTEM Table of Contents Page 2 1 Precautions 2 1 Operating Outboard without Battery 2B 1 Specific Gravity Readings 2B 1 Specific Gravity Cell Comparison Test 2B 2 Electrolyte 2B 2 Charging a Discharged Battery 2B 2 Winter Storage of Batteries 2B 3 Battery Charging System 2 3 Description 2 3 Battery Charging System Troubleshooting 2B 4 Stator Test Alternator Coils Only 2B 4 Voltage Regulator Test
164. Dual Outboard Ride Guide Steering Kit P N 9793344 Installation 7A 8 Installation Requirements 74 8 Steering Cable Installation Cable Routed Down Starboard Side of Boat to Port Outboard 7 9 Installing Steering Link Rod 74 9 Steering Cable Installation Cable Routed Down Port Side of Boat to Starboard Outboard 7 10 Tilt Tube 10 Installing Steering Cable 74 10 Installing Steering Link Rod 7A 11 Maintenance Instructions 74 11 Steering Coupler Assembly 7 12 Steering Coupler Installation 74 13 Ride Guide Steering Attachment Extension Couplers 14 Trim Tab Adjustment 7 14 Dual Outboard 7 14 Maintenance Instructions 7 14 Transom Mounted Ride Guide Attaching Installation 73770 1 7 15 Attaching Kit Installation 7 15 Clevis Attaching Kit Installation PIN 70599 4 7 16 Installation Instructions 7 16 Maintenance Instructions 7 17 Steering Cable Installation 74 18 Maintenance Instructions 7 18 Selecting Steering Cable and Remote Control bl x b 7 19 Remote Co
165. ECEMBER 1996 Rope Installation 5 Lubricate all components with low temperature grease 1 Route rope thru hole in sheave 2 Tie aknotin end of rope and place knot in recess 3 Wind rope b clockwise onto sheave when viewed from rewind spring side of sheave Y 54853 4 Lubricate shoulder on sheave shaft a with low 5 temperature grease and install lever as shown sheave shell Lever Wave Washer Flat Washer Sheave Spring Bushing Shaft Bushing Rewind Spring Spring Retainer Plate 6 Assemble sheave components as shown 54854 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7C 5 7 Install spring bushing and shaft bushing b 10 Push starter rope thru rope guide a then sheave assembly into rewind housing 8 Install spring retainer plate a over sheave shaft Use a thin shaft screwdriver to engage tab into in ner loop of rewind spring 11 Place new locking tab washer b cupped side facing down on sheave shaft 12 Thread nut c left hand thread finger tight on shaft 7 6 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 90 814676R1 DECEMBER 1996 cM Adjusting Rewind Spring Tension NOTE Check operation of rewind starter before bending tabs against nut 1 Tie a slip knot in starter rope approximately 12 in 805mm from end of Check rewind operatio
166. ER 1996 Leak Down Check Pump and Manifold Assembly NOTE Scribe d pump housing and manifold before disassembly 1 Debris or chips between valve and seat a usu ally imbedded in rubber valve seat Nicked or deteriorated O ring b Nicked deteriorated or misplaced O ring c 4 After reassembly insert driveshaft and check pump rotor resistance to turning housing halves can shift turn during reassembly Align scribe marks d carefully MID SECTION 5D 5 x 1 Leak Down Check Pilot Valve Leaks Past Ball and Seat Piston Assembly Assembly 1 Debris or chips between valve and seat usually Unit will trim to full or near full down position and then imbedded in rubber valve seat will begin to trim up while trim switch is held in 2 Pilot valve installed from non chamfered end of mode spool results in nicked or damaged O ring If trim switch is released outboard can be pushed by 3 Nicked or deteriorated O ring hand down to the point where trim UP started A leak path is created between the UP side of the cyl inder and the reservoir The trim system will leak down until the trim port in cylinder is covered 1 Inspect balls and seats in piston assembly for de bris or damage Repair or replace balls seats 51143 21399 a Ball and Seat Check All For Debris or Damage a Valve and Seat b Pilot Valve O ring c O ring Leak Down Check Manual Release Valve 1 Debris or chips under
167. EY Service Manual Outline Section 1 Important Information Section 2 Electrical amp Ignition Ignition System B Battery Charging System amp Starting System C Timing Synchronizing amp Adjustment D Wiring Diagrams 5 B Power Trim Design C Power Trim Design 11 D Power Trim Design III E Power Trim Design IV Manual Tilt System Design Il G Manual Tilt System Design IV Section 6 Lower Unit A Lower Unit B Jet Drive A Outboard Motor Installation Attachments B Tiller Handle and Co Pilot C Rewind Starter Section 8 Oil Injection System D et gt T c o lt o 3 go O 5 c 5 90 814676R1 1996 iii Important Information Electrical amp Ignition Fuel System amp Carburetion 4 Mid Section Outboard Motor Installation Attachments Cil Injection System EY Notice Throughout this publication Dangers Warnings and Cautions accompanied by the International HAZARD Symbol are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed in correctly or carelessly OBSERVE THEM CARE FULLY These Safety Alerts alone cannot eliminate the haz ards that they signal Strict compliance to these spe cial instructions when performing the service plus Common Sense
168. Flow Diagrams Design Il EB TRIM UP ES stn neon OIL UNDER PRESSURE RETURN OIL SEDENS 555559525052 S KD Oi manere Sotas 51644 5C 4 MID SECTION 90 814676R1 DECEMBER 1996 Design Il TRIM DOWN RESERVOIR AND FEED OIL OIL UNDER PRESSURE 90 814676R1 DECEMBER 1996 MID SECTION 5C 5 Design Il HYDRAULIC TILT RESERVOIR AND FEED OIL 5 5 OIL UNDER PRESSURE RETURN OIL 5C 6 MID SECTION 90 814676R1 DECEMBER 1996 Design Il MAXIMUM TRIM BLOW OFF C RESERVOIR AND FEED OIL p OIL UNDER PRESSURE B RETURN OIL ees 5555 SE ETT SEELEY 90 814676R1 DECEMBER 1996 MID SECTION 5C 7 Design Il SHOCK FUNCTION UP RESERVOIR AND FEED OIL UNDER PRESSURE RETURN OIL 5 8 MID SECTION 90 814676R1 DECEMBER 1996 Design Il ES SHOCK FUNCTION RETURN Design Il MANUAL TILT Troubleshooting Determining if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys tem is at fault Trouble Chart Outboard will not trim up or down Determine if Power Trim pump Outboard trims up will not trim down motor operates when appro priate trim circuit is activated Outboard trims down will not trim up Pum Outboard will not return complete operates Pump motor does not operate ly to down p
169. Fluid or ATF Type F FA or Dexron Il 90 814676R1 DECEMBER 1996 Motor and Electrical Tests Repair Trim Pump Motor Test Do not perform this test near flammables or ex plosives as a spark may occur when making connections 1 Disconnect orange motor wire and black mo tor wire from relay switch wiring harness 2 Connect a 12 volt power supply to motor wires positive to orange negative to black results in motor up direction Positive to black negative to orange results in motor down direction Motor should run 3 If motor does not run disassemble motor and check components Thermal Overload Switch Test IMPORTANT thermal overload switch has been activated pump motor cannot be tested for a minimum of one minute After this period switch should close reset itself and pump motor may be operated Perform the following check s only if switch does not reset itself MOTOR ASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated If full continuity is not indicated disassemble motor and recheck switch per instructions following 90 814676R1 DECEMBER 1996 a Motor Wire Black b Motor Wire Orange MOTOR DISASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated 51193 If full continuity is not indicated clean switch contact surfaces using an i
170. Hold drive key in place using Quicksilver 2 4 Marine Lubricant 54757 8 Lubricate inside diameter otthe water pump body Gear Housing Installation with Quicksilver 2 4 C Marine Lubricant AWARNING When installing gear housing remove and iso late spark plug leads from spark plugs to avoid accidental outboard starting 1 Remove and isolate spark plug leads 2 Tilt outboard to full up position and engage tilt lock lever 3 Install plate a ribbed side down and seal b tapered side up into gear housing Lubricate in 9 Rotate drive shaft clockwise while pushing water side of seal with Quicksilver 2 4 C Marine Lubri pump body down over impeller cant a Water Pump Body b Turn Drive Shaft Clockwise 54752 90 814676R1 DECEMBER 1996 LOWER UNIT 6 25 4 Install rubber seal a to drive shaft NOTE Outboard S N 0C295675 and above will not have seal on drive shaft due to improved lower end cap design 51188 5 Shift gear housing to forward position propeller shaft will not rotate counterclockwise 6 Install shift shaft guide 54751 7 Apply Quicksilver 2 4 C Marine Lubricant to drive shaft splines shift shaft splines and 1 0 of water tube seal DO NOT apply lubricant to top of shift shaft or drive shaft 6A 26 LOWER UNIT 8 Install water tube a int
171. IMPORTANT If cut or damaged O rings found inspect machined surfaces for scoring burrs or debris 5G 16 MID SECTION c 3 Checkfor discharged accumulator 35 to 50 Ib ft 47 68 N m of pulling force must be attained when tilting outboard from full down to full up position If more than 50 Ib ft 68 N m of force is required replace accumulator 50431 a Weight Scale b Valve Lever open position 90 814676R1 DECEMBER 1996 Manual Tilt System Removal CAUTION Remove cowling and remove all spark plug leads from spark plugs to prevent accidental starting while servicing outboard Service or installation of the tilt system may re sult in loss of pressure in the shock cylinder If the outboard is notin the full down position such loss of pressure will cause the engine to fall to the full down position with a potential for damag ing engine or causing personal injury To avoid such injury support outboard in the up position using tilt lock lever Manual tilt system is pressurized Accumulator must be removed when shock rod is in the full up position prior to servicing otherwise oil spray back may occur 1 Support outboard in the up position using tilt lock lever 2 Remove link rod 51143 a Link Rod b Accumulator 90 814676R1 DECEMBER 1996 3 Position piece of wood under transom bracket instead of tilt lock for access of removing pin Use suitable punch to remove
172. ING HARNESS RED Red 3 TAN Tan WHT White YEL Yellow LIT Light 6 2 DRK Dark BLK YEL 1 2D 18 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION Table of Contents Specifications Special Tools Fuel System Carburetor Fuel System Fuel Pump Fuel Pump General Information Fuel Pump Description Operation Checking for Restricted Fuel Flow Caused by Anti Siphon Valves Testing Troubleshooting Fuel Pump Fuel Pump Removal Electric Start Model Fuel Pump Disassembly Fuel Pump Exploded View Design 1 Cleaning and Check Valve Reassembly Design 1 Fuel Pump Installation Design 1 Fuel Pump Exploded View Design 2 Cleaning and Inspection Check Valve Reassembly Design 2 Fuel Pump Installation Design 2 Carburetion System Fuel System Troubleshooting Troubleshooting Charts Checking for Restricted Fuel Flow Caused by Anti Siphon Valves Carburetor Adjustments Initial Starting Adjustment Idle Speed Adjustment Idle Mixture Screw Adjustment Float Adjustment Float Level and Float Drop Adjustment Float Level WMA7B Carburetor Float Drop Carburetor Only Float Level WMA9 Carburetor Float Drop WMA9 Carburetor Only Main High Speed Jet Adjustm
173. INSTALLATION ATTACHMENTS OUTBOARD MOTOR INSTALLATION ATTACHMENTS Table of Contents Page Installing Outboard Motor on Transom 1 Determining Recommended Outboard Mounting 1 Locate Centerline of Boat Transom 7 1 Drilling Outboard Mounting Holes 7 2 Lifting Outboard 7 2 Securing Outboard to Boat Transom 7A 3 Securing Outboard to Boat Transom Using Optional Outboard Mounting Kit P N BIS SAT a exei eS nds 7A 3 Single Cable Single Outboard Ride Guide Steer ing Attaching Kit P N 19608A3 and P N 19609A2 Installation 7 4 Component Removal Tiller Handle Models reso RR RE ene m 7 4 Steering Bracket Installation Tiller Handle MOde lS aoi ace 7 4 19608 3 Ride Guide Steering Attaching Kit Installation Steering Cable Routed for Star board Entry into Outboard Tilt Tube 7A 4 Installing Ride Guide Cable to Outboard Tilt Uo PTT 7 4 Installing Steering Link Rod 74 5 19609A 2 Ride Guide Steering Attaching Kit Installation Steering Cable Routed for Port Entry into Outboard Tilt Tube 7 6 Tilt Tube 7 6 Installing Ride Guide Cable to Outboard TUBS HT 7 6 Installing Steering Link Rod 7 7 Maintenance Instructions 7 7 Single Cable
174. Ib ft 47 Tab Washers Bend Over Flat of Jam Nuts Cable Attaching Nut 7 18 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 5 Torque Ride Guide cable attaching nut which secures cable to guide tube to 35 Ib ft 41 5 N m below Install locking sleeve over cable at taching nut and secure with cotter pin Spread ends of cotter pin NOTE Some Ride Guide steering cables may not be equipped with locking sleeve and cotter pin If cable being installed does not have these parts disregard instructions to install them After installation is completed and before oper ating outboard check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interference free movement h AT 50568 Maintenance Instructions Lubrication and maintenance inspection is owner s responsibility and must be performed at intervals as specified following Normal Service Every 50 hours of operation or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation in salt water area is considered Severe Service CAUTION Core of steering cable must be fully retracted into cable housing before lubricating cable If cable is lubricated while extended hydraulic lock of cable could occur 1 Lubricate outb
175. If a reading resembling a short is ob tained this would be acceptable Copper wire is an excellent conductor but it will have a no ticeable difference in resistance from cold to hot tempera tures Reasonable variations from these readings are ac ceptable 4 f meter readings are not as specified replace ignition coil 90 814676R1 DECEMBER 1996 c d Stator Test Red Stator Electric Start Engines 1 Disconnect all stator leads 2 Use a VOA meter and perform the following checks Test Leads To GRN WHT and WHT GRN R x 100 YEL and YEL Manual Start Engines Ohm Test Leads To PX Reading GRN WHT and WHT GRN R x 100 660 710 BLK WHT and BLK R x 100 130 145 YEL and YEL 0 17 0 19 NOTE Above resistance readings are for a cold en gine room temperature Resistance will increase if engine is warm If meter readings are other than specified replace stator 90 814676R1 DECEMBER 1996 Stator Test Black Stator Disconnect all stator leads 2 Use a VOA meter and perform the following checks 9 AMP Stator Rx1000 5 7 8 0 1000 No Reading R X 1000 No Reading 16 AMP Stator 398 9710A33 amp 398 9710A42 Test Leads To Ohm Reading 1000 1000 1400 R X 1000 No Reading R X 1000 No Reading Rx 10 50 NOTE Above resistance readings are for a cold en gine room temperature Resistance will increase if engine is warm If meter readings are other t
176. Low Oil Sensor Warning Module Overheat Switch Enrichment Valve 90 814676R1 DECEMBER 1996 YEL BLK BLK 14 20 Fuse 15 Voltage Regulator Rectifier 16 Switch Box 17 Ignition Coil 1 Cylinder 18 Ignition Coil 2 Cylinder 19 Ignition Coil 3 Cylinder 20 Ignition Coil 4 Cylinder 21 Emergency Stop Switch 22 To Female Connector on Remote Control Harness Plug 23 To Bottom Cowl ELECTRICAL AND IGNITION 20 3 f Wiring Diagram Model 30 Jet Tiller Handle with 16 Amp Red Stator BLK BLU BRN GRY GRN ORN PNK PUR RED Tan WHT YEL LIT 2 1 2D 4 ELECTRICAL AND IGNITION Black Blue Brown Gray Green Orange Pink Purple Red Tan White Yellow Light Dark 90 814676R1 DECEMBER 1996 c Wiring Diagram Model 40 Electric Start with 9 Amp Black Stator BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark STATOR 90 814676R1 DECEMBER 1996 TRIGGER 6 7 179 95 c FUEL o ee p A E 2 7 M UM dl T 74 6 a RECTIFIER TEMPERATURE GAUGE SENDER op j STARTER 1 x SOLENOID x a ta TO TAN FEMALE CONNECTOR ON REMOTE CONTROL HARNESS PLUG 50504 ELECTRICAL AND IGNITION 2D 5
177. Lubricant when light oil is specified or with Quicksilver Needle Bear ing Assembly Lubricant whenever grease is speci fied Quicksilver part numbers of lubricants sealers and locking compounds are listed in the Tool Catalog and in accessories brochures A torque wrench is essential for correct reassembly of powerhead DO NOT attempt to reassemble pow erhead without using a torque wrench Attaching bolts for covers housings and cylinder heads MUST BE torqued by tightening bolts in 3 progressive steps following specified torque sequence until specified torque is reached see Example following Example lf cylinder cover attaching bolts require torque of 70 Ib in 81 kg cm a tighten all bolts to 20 Ib in 2 2 following specified torque se quence b tighten all bolts to 50 Ib in 5 5 fol lowing torque sequence then finally c tighten all bolts to 70 Ib in 7 7 N m following torque se quence Powerhead torques are listed in General Informa tion Powerhead preceding POWERHEAD 4 31 Crankshaft Reassembly 1 Lubricate main bearing outer race with Quicksil ver Needle Bearing Assembly Lubricant and place needle bearings on race Outer Race Needle Bearing Assembly Lubricant Needle Bearings 56 Required m 2 Install bearing race with needle bearings in place on crankshaft Secure both halves of race togeth er with snap ring 54711 Instal
178. N OIL GAS PRESSURE 300 700 P S I 5F 8 MID SECTION 90 814676R1 DECEMBER 1996 Design 2 TILT DOWN OIL UNDER PRESSURE 0 RETURN OIL GAS PRESSURE 300 700 P S I 51657 90 814676R1 DECEMBER 1996 MID SECTION 5F 9 Design 2 SLOW DOWN UNDER HIGH THRUST Design 2 UNDER WATER STRIKE VALVES OPEN 90 814676R1 DECEMBER 1996 MID SECTION 5F 11 Design 2 SHOCK FUNCTION VALVES CLOSED EY Q Manual Tilt Flow Diagrams Design 3 TILT UP E RETURN OIL GAS PRESSURE 300 700 P S I 51661 90 814676R1 DECEMBER 1996 MID SECTION 5F 13 Design 3 TILT DOWN p OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 5 14 MID SECTION 90 814676R1 DECEMBER 1996 Q Design 3 SLOW TILT DOWN UNDER HIGH THRUST OIL UNDER PRESSURE RETURN OIL GAS PRESSURE 300 700 P S I 51663 90 814676R1 DECEMBER 1996 MID SECTION 5F 15 gt Design 3 UNDER WATER STRIKE VALVES OPEN 5F 16 MID SECTION 90 814676R1 DECEMBER 1996 Q Design 3 SHOCK FUNCTION VALVES CLOSED Hydraulic System Troubleshooting Refer to disassembly reassembly instructions fol lowing if disassembly is required when servicing IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be d
179. O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a O ring 5D 6 MID SECTION 90 814676R1 DECEMBER 1996 cM Troubleshooting Flow Diagram Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt bolt hole in eight hours Example b Outboard lowers during acceler ation Inspect Manual Release Valve Result Result Manual release valve and or O ring damage Manual release valve and O rings appear to be OK Replace O rings Replace defective valve and O rings Result O rings appear to be OK Oylin der bore and memory piston are OK Replace O rings and pro ceed Inspect O rings on Pilot Relief Valve located in manifold assem bly Results Results O ring failure O rings appear to be OK Re place O rings Inspect Memory Piston Replace O rings O ring Results Results All components appear to be OK O ring or Cylinder Bore Defective Replace Manifold and Pump Assembly Replace O ring or Components 90 814676R1 DECEMBER 1996 MID SECTION 5D 7 Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Inspect Manual Release Valve Results Results Manual release valve and or O ring damage Manual release valve and O rings appear to be OK Replace O rings and proceed
180. OTE Crankshafts that use Design 1 and Design 3 1 Thoroughly clean crankshaft splines with solvent lower end caps shown have a replaceable seal in and dry with compressed air the bottom of the crankshaft This seal protects the 2 Drive seal carrier squarely into end of crankshaft drive shaft splines Design 2 type lower end caps using a block of wood to protect seal carrier have the seal incorporated in the end cap Install seal carrier to the dimension shown CRANKSHAFTS USING DESIGN 1 LOWER END CAP 1 Install new O Ring seal into seal carrier on end of crankshaft 2 Lubricate seal with 2 4 Marine Lubricant 5 32 4mm 1 o gt lt Hi 4 41 a Seal Carrier CRANKSHAFTS USING DESIGN 3 LOWER END CAP 1 Install new O Ring seal into seal carrier on end of crankshaft 2 Lubricate seal with 2 4 Marine Lubricant Design 1 Type Lower End Cap O Ring Seal Seal Carrier Lubricate with 2 4 C Marine Lubricant Design 3 Lower End Cap b O Ring Seal Lubricate with 2 4 C Marine Lubricant 90 814676R1 DECEMBER 1996 POWERHEAD 4 37 End Cap Reassembly 4 ball bearing into lower end cap with press ock LOWER END CAP 1 Install O Ring Seal into seal groove 2 Apply Loctite Grade A 271 to outer diameter oil seals and press into end cap using proper mandrel as shown Wipe off excess Loctite 3
181. Operated Valve Filter 2 shown for clarity Shock Return Valve Up Circuit Suction Port Pump Down Circuit Suction Port Fill Cap 5E 18 MID SECTION 880 1110 40 60 1220 1420 75 125 540 9 mE aN 250 400 40 60 90 75 125 m Shuttle Valve n Up Pressure Operated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Relief Valve S Tilt Relief Piston t Memory Piston u Shock Piston v Impact Relief Valve w Oylinder 90 814676R1 DECEMBER 1996 Manual Tilt To manually tilt the outboard engine the owner will need to back out the manual release valve p 3 4 turns With the valve backed out the internal pas sages inside the manifold are connected together These passages connect both the cylinder down and up cavities together along with the reservoir allow ing the engine to be raised or lowered Piston rod a movement will continue until the manual release valve p is closed locking the fluid inside of the cylin der and manifold 90 814676R1 DECEMBER 1996 MID SECTION 5E 19 Troubleshooting Support outboard with tilt lock pin when servicing power trim system IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check bal
182. RBURETION 90 814676R1 DECEMBER 1996 NOTE Carburetor float bowl primer fitting design 7 Remove float needle and baffle from carburetor be identified below DESIGN 1 DESIGN 2 DESIGN 3 Float Needle Baffle Remove main nozzle and venturi from carbure tor oon 52027 52015 a Main Nozzle b Venturi a Pivot Pin b Float 90 814676R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 23 9 Remove main jet from carburetor 10 Remove vent jet from carburetor WMA7B CARB 52015 a Vent Jet 11 Remove idle mixture screw and spring from car a Main Jet buretor 52015 52026 a Idle Mixture Screw a Main Jet b Spring 3 24 FUEL SYSTEM AND CARBURETION 90 814676R1 DECEMBER 1996 14 12 Remove throttle return spring from throttle shaft 14 Remove throttle shaft from carburetor 52021 a Throttle Shaft 52016 a Throttle Return Spring b Throttle Shaft Cleaning and Inspection 13 Remove screws securing throttle plate to throttle 1 Carefully inspect carburetor body and fuel bowl shaft for cracks stripped threads plugged or restricted passages and passage plugs that show signs of leakage 2 Thoroughly clean all carburetor parts with a mild cleaning solution that will not damage rubber or plastic to remove dirt gum and varnish that may have accumulated 3 After washing parts blow parts dry with com pressed air Be sure to
183. REW reed stop 9 16 NUT reed stop screw PISTON PISTON PIN STANDARD PISTON PISTON PIN 015 O S DESIGN II PISTON PISTON PIN 030 O S PISTON PISTON PIN STANDARD PISTON PISTON PIN 015 O S DESIGN PISTON PISTON PIN 030 O S LOCK RING piston pin PISTON RING STANDARD PISTON RING 015 O S DESIGN II PISTON RING 030 O S PISTON RING STANDARD PISTON RING 015 O S DESIGN I PISTON RING 030 O S CONNECTING ROD AND CAP ASSEMBLY SCREW cap to rod NEEDLE BEARING piston pin WASHER needle locating NEEDLE BEARING crank pin CENTER MAIN BEARING ASSEMBLY DOWEL PIN center main bearing NEEDLE BEARING RACE outer SNAP RING outer race SCREW center main bearing 1 DRIVER GEAR KEY driver gear CARRIER ASSEMBLY DESIGN FS VINE e A NIA gt A mi t c AR 4 8 1 1 v 8 v o 90 814676R1 DECEMBER 1996 POWERHEAD 4 9 CRANKCASE COVER BOLTS 17 5 Ib ft 23 5 Powerhead Torque 16 5 Ib ft 22 5 11 EXHAUST COVER ee 2 zat 1 2 i AL l I NS zi Ye 2 x NN V 100 Ib in 11 5 N m qe i 2 17 gt S Ir
184. Replace 1 Check for an open connection or cut wire 2 Replace 1 Check for an open connection 2 Check for an open connection 3 Check for an open connection 4 Replace 1 Replace fuse Locate the cause of the blown fuse Check electrical wiring for a shorted circuit 2 Replace 3 Check for an open connection or cut wire 4 Check for a loose or corroded con nection 1 Check wire connections 4 for loose or corroded condition 2 If voltage is present at connections 4 when the appropriate trim button is pressed then motor is faulty Replace motor 1 Replace 90 814676R1 DECEMBER 1996 3 Remove the trilobe pin Q Power Trim System Removal 1 Tilt outboard to the full up position and support 4 Drive out the upper pivot pin with tilt lock pin xU l i a J 2 2 2 2 2 9 Trilobe Pin 9 A 39464 b Upper Pivot Pin a Tilt Lock Pin 5 Remove the sacrificial anode 2 Disconnect the power trim wire harness and re move clamp 55331 J a a Sacrificial Anode 55264 a Power Trim Wire Harness Clamp b Harness MID SECTION 5E 27 90 814676R1 DECEMBER 1996 6 Use suitable punch to remove Drive Up lower pin Retain dowel pin DH Ore 51144 a Dowel Pin 7 Use suitable punch to drive out lower pivo
185. SECTION 5B 5 HYDRAULIC TILT RESERVOIR AND FEED OIL OIL UNDER PRESSURE _ RETURN OIL 51639 5B 6 MID SECTION 90 814676R1 DECEMBER 1996 Design 1 MAXIMUM TRIM BLOW OFF GJ 1 RESERVOIR AND FEED OIL OIL UNDER PRESSURE RETURN OIL 51640 90 814676R1 DECEMBER 1996 MID SECTION 5B 7 c Design 1 EB SHOCK FUNCTION UP E 1 RESERVOIR AND FEED OIL OIL UNDER PRESSURE 51641 5B 8 MID SECTION 90 814676R1 DECEMBER 1996 Q Design 1 SHOCK FUNCTION RETURN 1 RESERVOIR AND FEED OIL 2554 OIL UNDER PRESSURE 51642 90 814676R1 DECEMBER 1996 MID SECTION 5B 9 3 Design 1 MANUAL 1996 90 814676 1 Q Troubleshooting Determine if Problem is Electrical or Hydraulic Refer to the following chart to determine which sys tem is at fault Trouble Chart Outboard will not trim up or down Determine if Power Trim pump Outboard trims up will not trim motor operates when appro down priate trim circuit is activated Outboard trims down will not trim up Pump motor operates Outboard will not return complete ly to down position or returns part way with jerky motion Outboard thumps when shifted Outboard trails out when backing Refer to Hydraulic System off throttle at high speed Troubleshooting Pump motor does not operate Outboard will not hold a trimmed position or will not remain tilted for any extended period
186. Sharp Edge Towards Propeller b Seal Lip or Seal Towards Reverse Gear Ball Bearing d Flush e Wood Forward Gear Race Installation 1 Install shim s 2 carefully drive bearing race into gear housing un til seated as shown a Mandrel 91 31361 b Shim s Bearing Race d Lead Hammer 90 814676R1 DECEMBER 1996 Drive Shaft Reassembly and Installation 1 m Press tapered bearing onto drive shaft until inner bearing race bottoms on shoulder 54798 Power Head End of Drive Shaft Shoulder Tapered Bearing Outer Race Install shim s Drive bearing into gear housing until seated NEN k d ot oO 54799 Driver Rod Mandrel 91 86290 Bearing Race Shim s LOWER UNIT 6A 19 4 Apply Loctite Grade A onto threads of new pin ion nut and install components 5 Clamp drive shaft in soft jawed vise and torque pinion nut to 50 Ib ft 67 8 Hi ML SS dei Ww 54771 a Forward Gear Assembly b Drive Shaft c Pinion Gear d Pinion Nut Hidden Flat Side Away from Pinion Gear Checking Pinion Gear Depth IMPORTANT Read entire shimm
187. TEM 90 814676R1 DECEMBER 1996 Q Pump Drive Assembly O RING RETAINING BOLTS USE LOCTITE GRADE A BUSHINGS ON BOLT THREADS APPLY NEEDLE BEARING TORQUE BOLTS TO ASSEMBLY LUBRICANT TO 45 Ib in 5 1 N m DRIVEN GEAR SHAFT DRIVEN GEAR 50448 50448 Pump Drive System OIL PUMP ZZ 2272222 35 SST 2727777 2 CLA CRANKSHAFT 50448 90 814676R1 DECEMBER 1996 OIL INJECTION SYSTEM 8 3 EY Oil Pump to Powerhead Assembly Bolt 2 Each Oil Pump O ring Large O ring Small Bearing Driven Gear Torque Specifications 45 Ib in 5 1 N m Quicksilver Lubrication Sealant Application Points Loctite Grade A 92 32609 1 B Needle Bearing Assembly Lubricant WN 92 42649 1 KS lt FS U7 N Y N 8 4 OIL INJECTION SYSTEM 90 814676R1 DECEMBER 1996 Q Set Up Instructions for Oil Injection System CAUTION Oil injected engines additionally must be run on a 50 1 gasoline oil mixture in the fuel tank for the first 15 gallons of fuel Refer to engine break in procedure in the Operation amp Maintenance Manual CAUTION If an electric fuel pump is to be used on engines With oil injection the fuel pressure at the engine must not exceed 2 psig If necessary install a pressure regulator between electrical fuel pump and engine and set at 2 psig maximum Filling the Oil Injection Sy
188. XTURE SCREW ADJUSTMENT 1 With outboard in test tank or boat and outboard in water preset carburetor idle mixture screw at 1 1 4 turns out from a lightly seated position a Idle Mixture Screw 2 Start outboard and allow to warm up for approxi mately five minutes 3 With outboard running shift into forward gear Slowly turn idle mixture screw counterclockwise until the corresponding cylinders start to load up or fire unevenly due to an over rich condition 4 Slowly turn idle mixture screw clockwise until the cylinders fire evenly and engine picks up speed 5 Continue turning screw clockwise until too lean a mixture is obtained outboard slows down and misfires 6 Setidle mixture screw at a point midway between TOO RICH and TOO LEAN When in doubt set slightly RICH rather than TOO LEAN 7 Donotadjust leaner than necessary to attain rea sonably smooth idling TOO LEAN a mixture is a major cause of hard starting 90 814676R1 DECEMBER 1996 IDLE RPM ADJUSTMENT 1 Place outboard in test tank or boat and outboard in water Start outboard and allow to warm up for approxi mately five minutes With outboard running shift into forward gear and adjust idle RPM as follows a Remove throttle cable barrel from barrel re tainer Adjust idle RPM screw to attain an idle speed of 600 to 700 RPM with outboard run ning in forward gear Retighten nut on adjust ing screw a Idle RPM Screw b With end
189. a heavy load Usually improves ride in choppy water In excess can cause boat to veer to the left or right bow steer Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt pin one hole closer to transom Operating Down circuit will actuate the down sole noid located under engine cowl and close the elec tric motor circuit motor will run in opposite direction of the Up circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the down side of the tilt ram The tilt ram will move the engine downward to the desired angle MID SECTION 5C 1 Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running While operating up circuit tilt ram will continue to tilt outboard to full up position for trailering Tilting Outboard Up and Down Manually Before loosening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is loos ened With power trim installed the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns counterclockwise bes 50146 a Manual Release V
190. age Indicated Connect Voltmeter red lead to Point 3 No Voltage Indicated Connect Voltmeter red lead to Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to There is an open circuit between Point 2 Point 3 and positive battery ter Depress Down trim button minal Check for loose or corroded con nections Check wires for open circuit Battery Voltage Indicated No Voltage Indicated Pump motor wiring is defective Relay Switch is defective Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 5C 18 MID SECTION 90 814676R1 DECEMBER 1996 Troubleshooting the Up Circuit When Down Circuit Is OK Connect Voltmeter red lead to Point 8 and black lead to ground Depress the trim button Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3 Point 7 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 7 and 8 Battery Voltage Indicated No Voltage Indicated
191. all lubricated O ring to base of reservoir Carefully guide cylinder motor down onto drive shaft 3 Install end cap O ring and foam pad to cylinder 4 Torque screws to 13 Ib in 1 5 N m a Drive Shaft 51195 b O ring a End Cap b O ring Foam Pad 90 814676R1 DECEMBER 1996 MID SECTION 5C 33 9 Secure reservoir to manifold using four screws Torque screws to 70 Ib in 7 7 a Screw 10 Install E clip lubricated O rings and to manual release valve a b O ring c Manual Release Valve 11 Insert manual release valve into manifold and tighten snuggly Back release valve out 3 or 4 turns allowing trim rod installation a Manual Release Valve b Manifold 5C 34 MID SECTION cM 1 Install lubricated O rings and rod wiper to end cap Trim Rod Reassembly 51145 a Rod Wiper b Inner O ring C Outer O ring 2 Secure trim rod in soft jawed vise as shown 3 Slide end cap onto trim rod 51146 a End Cap 90 814676R1 DECEMBER 1996 p Trim Rod Piston Spanner Wrench Apply Loctite Grade A 271 to threads of trim rod Trim Rod Installation and install rod piston Tighten piston securely us ing trim cylinder spanner wrench 1 4 in x 5 16 in 1 Place trim cylinder in soft jawed vise long peg 2 Fill trim cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and
192. alve 5C 2 MID SECTION c Trim Angle Adjustment Operating some boats with engine trimmed to the full in trim angle not using trim adjustment pin a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after engine installation and after any trim adjust ments IMPORTANT Some boat motor combinations that do notusethe trim adjustment pin a and are trimmed to the full in trim angle will not experi ence any undesirable and or unsafe steering conditions during planing speed Thus not us ing trim adjustment pin may be desired However some boats with engine trimmed to the full trim angle at planing speed will cause undesir able and or unsafe steering conditions If these steering conditions are experienced under no circumstances should the engine be operated without the trim adjustment pin and without the pin adjusted in the proper holes to prevent un safe handling characteristics Water test the boat not using the trim adjustment pin If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment pin in proper hole to prevent unsafe han dling characteristics 90 814676R1 DECEMBER 1996 n NOTE It is recommended that ALL O rings be re placed when servicing tilt system Power Trim System Components Trim R
193. am Bore 5B 38 MID SECTION 7 Usinga suitable mallet drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flushed with swivel bracket a Pivot Pin Swivel Bracket C Trim Ram 8 Drive upper dowel pin RETAINED into its re spective hole until seated a Dowel Pin 9 Remove trim fluid fill screw Fluid level should be to bottom of threads Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF Type FA or Dexron II to trim system if necessary 10 Reinstall fill screw 11 Power trim may now be operated to lower out board to desired position Trim system is self bleeding 12 Reconnect spark plug leads to spark plugs 13 Reinstall top cowl 14 Connect battery leads to battery terminals 90 814676R1 DECEMBER 1996 cM MID SECTION POWER TRIM DESIGN Il Table of Contents Page Power Trim General Information 5C 1 Descrplioli oro hr re ERR 5C 1 Trimming Characteristics 5C 1 Trimming Outboard Up Out 5C 1 Trimming Outboard Down In 5C 1 Trailering Outboard 5C 2 Tilting Outboard Up and Down Manually 5C 2 Trim In Angle Adjustment 5C 2 Power Trim System Components 5C 3 Torque Specifications 5C 3 Quicksilver Lubricant Sealant Application POIDIS nad
194. an blue warning module lead at bullet horn and engine connection for engine overheat sensor located in engine cylinder head Use a jumper wire to ground tan blue warning module lead to engine ground Warning horn should sound If not check tan blue wiring between engine and warning horn for open circuit and check horn Warning Module Check if all warning module leads are connected to harness leads If so warning module may be faulty Using incorrect side mount remote control or igni See info on page 8 6 tion choke assembly Problem Warning Horn Stays On when Ignition Key is Turned to ON Position Engine Cold Possible Cause Corrective Action Engine overheat sensor If warning horn sounds a continuous the en gine overheat sensor may be faulty Disconnect tan blue overheat sensor lead at at bullet connection Turn ignition key to ON position If horn still sounds a continuous the warning module is faulty replace module and retest If horn stops sounding the engine overheat sensor is faulty Replace and retest Faulty Warning Module Check connections replace module Problem Warning Horn Sounds Intermittent Beep when Engine is Running Cil Level in Oil Tank Is Full Possible Cause Corrective Action Defective low oil sensor located in bottom of oil Disconnect both low oil sensor leads blue at bullet tank connections Connect an ohmmeter between sensor leads There should be
195. and Inspection 7C 3 Rewind Starter Reassembly 7C 4 Installing Used Rewind Spring 7 4 Installing New Rewind Spring 7C 4 Rope Installation 7 5 Adjusting Rewind Spring Tension E 90 814676R1 DECEMBER 1996 Rewind Starter Components 1 Nut Left Hand Thread 2 Tab Washer 3 Starter Housing 4 Starter Sheave 5 Starter Pawl 6 Screw 3 7 Lockwasher 3 8 Screw 2 9 Nut 2 10 Plate 11 Spring 12 Bushing 13 Spring 14 E Ring 15 Spacer 16 Washer 17 Lever 18 Wave Washer 19 Sheave Shaft 20 Starter Rope 21 Handle and Retainer 22 Cable 23 Screw 24 Washer 25 Washer 26 Screw 27 Spring 28 Cam 29 Screw 30 Actuator 31 Cotter Pin 32 Screw 33 Spring 34 Bushing 35 Retaining Ring 36 Rest Assembly 37 Seal 38 Primer Bulb 39 Tubing 40 Stop Switch Assembly 41 Boot Assembly 42 Cotter Pin 2 Torque Specifications 1 2 100 Ib in 11 Nm Quicksilver Lubricants and Service Aids E A 2 4 Marine Lubricant See Quicksilver Accessories Guide for part num bers 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7C 1 Rewind Starter Disassembly 4 Bend lock tabs a away from nut b 5 Remove nut b left hand thread turn clockwise A O to remove while supporting rewind assembly When disassembling
196. anual release valve 3 to 4 turns counterclockwise a Manual Release Valve MID SECTION 5E 5 v N p i POWER TRIM FLOW DIAGRAMS TRIM UP CIRCUIT Reservoir Oil Filtered Feed Oil Return Oil Oil Under Pressure Up Pressure 1625 40 60 2800 75 125 min Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure Operated Valve Filter 2 shown for clarity Shock Return Valve Up Circuit Suction Port Pump Down Circuit Suction Port Fill Cap 5E 6 MID SECTION Impact Relief P ressure 22 880 1110 40 60 1220 1420 75 125 r Tilt RE 250 400 40 60 540 990 75 125 lt Shuttle Valve Up Pressure Operated Valve Manifold Reverse Suction Valve Manual Release Valve Manifold Tilt Relief Valve Tilt Relief Piston Memory Piston Shock Piston Impact Relief Valve Oylinder 90 814676R1 DECEMBER 1996 c When the tr
197. apter Module and Switch Box Test ELECTRICAL AND IGNITION 2A 7 Ignition Troubleshooting Engines With Red Stator STEP 3 Switch Box BLU Wire Circuit Test e 84 re v O Ox 5 1 T BLU b 77 a a Connect Test Lead To BLU Wire Terminal On Switch Box b Connect Test Lead To Engine Ground 1 Use Multimeter DVA Tester 91 99750 Set switch position to 400 DVA 2 Crank engine and observe meter reading Voltage at 300 RPM cranking Voltage at 1000 4000 RPM Running 190 Volts 275 to 320 Volts TEST RESULTS e Voltage output is high The adapter module is de fective Replace adapter module Good voltage output Go to STEP 3 Switch Box BLU WHT Wire Circuit Test e No voltage output or low voltage output Go to STEP 5 Stator Adapter Module and Switch Box Test 2 8 ELECTRICAL AND IGNITION c f STEP 4 Switch Box BLU WHT Wire Circuit Test BLU WHT Z N EI ie Le n 5 9 go 1 o a 7 9 b a Connect Test Lead To BLU WHT Wire Terminal On Switch Box b Connect Test Lead To Engine Ground 1 Use Multimeter DVA Tester 91 99750 Set switch position to
198. ars to be o k cylinder bore and memory piston Replace O rings and proceed Inspect Transfer Valve Results Results No debris or defective components found Debris or defective components found in transfer valve Replace valve block Clean components using engine cleaner and compressed air or replace as necessary Replace defective O ring 90 814676R1 DECEMBER 1996 MID SECTION 5F 19 Troubleshooting Flow Chart Continued Outboard will not hold tilted position in reverse and or trails out during high speed deceleration with manual release valve lever in the lock run up position A CAUTION Tilt ram must be in full up position and accumu lator removed before manual tilt system disas sembly Inspect shock rod piston check valve s Results Results Debris or defective components found in check No debris or defective components found in check valve s valve s Clean check valve s components using engine clean Inspect transfer valve s er and compressed air or replace Results Results No debris or defective components found in Debris or defective components found in transfer valve s transfer valve s Inspect valve block Clean transfer valve s components using engine cleaner and compressed air or re place Results Results Debris found in valve block passages Clean valve block using engine cleaner and compressed air 5F 20 MID SECTION 9
199. ated Valve o Manifold Reverse Suction Valve p Manual Release Valve q Manifold r Tilt Relief Valve s Tilt Relief Piston SY i k e E t Memory Piston Shock Piston ax i MAXIMUM TILT v Impact Relief Valve w Oylinder Reservoir Oil Filtered Feed Oil Return Oil BOUL Oil Under Pressure Impact Relief Pressure 22 880 1110 40 60 1220 1420 75 125 90 814676R1 DECEMBER 1996 With the piston rod at maximum travel and due to rod movement the pressure inside of the trim cylin der w will increase to the pressure required to move the tilt relief piston s The tilt relief piston s pin opens the tilt relief valve Up pressure flows into the trim relief passage and returns back into the res ervoir 90 814676R1 DECEMBER 1996 MID SECTION 5E 11 9 ag a cM nn DOWN CIRCUIT d i k m n Reservoir Oil g Filtered Feed IM Return 9 m i p Oil Under Pressure Impact Relief P ressure 22 Up Pressure 1625 40 60 2800 75 125 5 min a Piston Rod b End Cap 880 11
200. ation Remove and isolate spark plug leads from spark plugs when installing propeller 1 Remove and isolate spark plug leads from spark plugs 2 Apply a thin coat of lubricant to propeller shaft splines with Quicksilver 2 4 C Marine Lubricant 3 Install components as shown Flo Torg Drive Hub Propellers a a Forward Thrust Hub b Propeller Nut Retainer c Propeller Nut Flo Torq Il Drive Hub Propellers e T b a Forward Thrust Hub Replaceable Drive Sleeve Rear Thrust Hub Propeller Nut Retainer Propeller Nut 4 Tighten propeller nut to 55 Ib ft 75 N m Bend tabs against nut a Propeller Nut Torque To 55 Ib ft 75 N m b Bend Tabs Against Nut LOWER UNIT 6A 27 5 Install trim tab a Torque to 20 Ib ft 27 1 7 Check shift operation as follows Nm a Place shift lever in forward gear Gear hous 6 Install nylon plug b ing should ratchet when propeller shaft is turned clockwise and resistance should be felt when propeller shaft is turned counter clockwise b Place shift lever in neutral Propeller shaft should rotate freely in either direction c While rotating propeller shaft place shift le ver in reverse gear Resistance should be felt when propeller shaft is rotated in either direc tion IMPORTANT If shift operation is not as de
201. attery See Electrolyte Level and Charging a Discharged Bat tery preceding If battery will NOT accept a satisfactory charge re place battery If battery accepts a satisfactory charge determine the cause of the charging system problem as follows Visually check the following 1 Check for correct battery polarity red cable to positive battery terminal If polarity was incor rect check for damaged rectifier See Rectifier Test following Check for loose or corroded battery connections Visually inspect wiring between stator and bat tery for cuts chafing and disconnected loose or corroded connections 4 Excessive electrical load from too many acces sories will cause battery to run down If visual inspection determines that battery connec tions and wiring is OK perform the following stator and rectifier test 2B 4 ELECTRICAL AND IGNITION PAS Stator Test Alternator Coils Only NOTE Stator can be tested without removing from engine 1 Disconnect both yellow stator leads 2 Use an ohmmeter and perform the following test 3 Replace stator if readings are outside ranges shown STATOR TEST BLACK STATOR 9 AMP Stator 398 818535A5 Ohm Test Leads To E Reading YEL and YEL 8 1 1 9 AMP Stator 398 8778A Ohm Test Leads To EX Reading YEL and YEL 5 1 0 16 Stator 398 9710A33 amp 398 9710A42 Test Leads To Ohm Reading x 1 YEL and YEL 10
202. b MUST align with hole c 54802 34905 4 Apply thin coat of Quicksilver Needle Bearing As 7 Place propeller shaft into forward gear sembly Lubricant on flat side a of cam follower b and install cam follower y 2 0 2 cif 5 Install cross 54764 Bearing Carrier Installation 1 Install O ring a 2 Apply 2 4 C Marine Lubricant on O ring a and seal lips b 3 Coat surfaces c with Special Lubricant 101 a Apply Pressure in this Direction b Cross Pin 90 814676R1 DECEMBER 1996 LOWER UNIT 6A 21 4 Push bearing carrier into gear housing while ro tating drive shaft to engage pinion gear teeth with reverse gear teeth 5 Install alignment key a 54807 IMPORTANT For proper retention between hous ing and cover nut it is recommended that PLAS TIC cover nut NOT be reused Replace as re quired 6 Apply Quicksilver Special Lubricant 101 onto threaded area of gear housing b 6A 22 LOWER UNIT cM Install cover nut a with the word OFF visible Torque cover nut to 100 Ib ft 136 using cover nut tool 91 91947 b Bend one of lock tabs c into slot in cover nut Bendremaining tabs towards front of gear hous ing 90 814676R1 DECEMBER 1996 c
203. b in 6 2 N m FUEL SYSTEM AND CARBURETION 3 11 Carburetion System Fuel System Troubleshooting Problems which sometimes are thought to be caused by the fuel system may be something com pletely different Troubles that are caused by items 1 thru 5 listed below also may give the impression that a problem exists in the fuel system 1 Spark Plugs Ignition Spark Voltage Cylinder Compression Reed Valves B wn Ignition Timing Troubleshooting Charts Problem Engine Turns Over But Will Not Start or Starts Hard When Cold Improper starting proce Check procedure as out dure lined in Operation and Maintenance Manual Check fuel in fuel tank and replace or add Fuel tank empty improp erly mixed fuel contami nants water dirt etc in fuel Fuel tank air vent closed Air vent must be open and or restricted free from contaminants A pinched or restricted Check and replace as fuel line needed Dirty or restricted fuel fil Check replace or clean ter Enrichener Valve not op erating Check enrichener system Refer to Enrichener Sys tem following An inlet needle in carbu retor that is stuck open or closed A needle stuck open will cause a flood ing condition A needle stuck closed will prevent fuel from entering carbu retor Remove clean or replace Anti siphon valve restrict Refer to Checking for re ing fuel flow stricted Fuel Flow caused by Anti
204. back into the pump j through the open down pressure operated valve f and enters the pump as supply for the up circuit 90 814676R1 DECEMBER 1996 MID SECTION 5E 7 cM TILT CIRCUIT m 2 00 m N Reservoir OL 3 By Filtered Feed Oil Return Oil Under Pressure Impact Relief P ressure 22 880 1110 40 60 inu i 1220 1420 75 125 S Up Pressure S i Relief P N 250 400 40 60 540 990 75 125 a Piston Rod m Shuttle Valve b End Cap n Up Pressure Operated Valve Electric Motor o Manifold Reverse Suction Valve d Reservoir Oil p Manual Release Valve e Down Pressure Regulating Valve q Manifold f Down Pressure Operated Valve r Tilt Relief Valve g Filter 2 shown for clarity s Tilt Relief Piston h Shock Return Valve t Memory Piston i Up Circuit Suction Port u Shock Piston Oil Pump v Impact Relief Valve k Down Circuit Suction Port w Cylinder Oil Fill 5E 8 MID SECTION 90 814676R1 DECEMBER 1996 Tilt Up In the up mode as the piston rod a extends from the cylinder w th
205. best possible maintenance during inactive peri ods to ensure a good serviceable battery in spring When ready to place battery back in ser vice remove excess grease from terminals a small amount is desirable on terminals at all times recharge again as necessary and reinstall battery 90 814676R1 DECEMBER 1996 Hydrogen and oxygen gases are produced dur ing normal battery operation or charging Sparks or flame can cause this mixture to ignite and ex plode if they are brought near the battery Sulphuric acid in battery can cause serious burns if spilled on skin or in eyes Flush or wash away immediately with clear water Battery Charging System Description The battery charging system components are the al ternator rectifier and battery Alternating current generated in alternator coils flows to the rectifier which changes the alternating current to direct cur rent for charging the battery a Alternator b Rectifier c Battery The charging system may be damaged by 1 re versed battery cables 2 running the engine with bat tery cables disconnected and cable ends touching each other 3 an open circuit such as a broken wire or loose connection and 4 shorting across the bat tery terminals ELECTRICAL AND IGNITION 2B 3 Battery Charging System Troubleshooting A fault in the battery charging system usually will cause the battery to become undercharged Check battery electrolyte level and charge b
206. block cover GASKET cylinder block cover SCREW cylinder block cover 1 COVER ASSEMBLY transfer port GASKET transfer port cover SCREW transfer port cover 5 8 GASKET cylinder block to baffle plate PLAT E baffle exhaust manifold GASKET baffle plate to exhaust cover COVER exhaust manifold END CAP ASSEMBLY lower DESIGN I II O RING lower end END CAP OIL SEAL Design End Cap SEE OIL SEAL Design Il End Cap BELOW OIL SEAL Design End Cap FOR S N BALL BEARING lower end cap END CAP ASSEMBLY lower DESIGN III O RING lower end END CAP OIL SEAL SEE BELOW BALL BEARING lower end cap FOR S N SHIM lower end cap 005 10 SCREW lower end SCREW manifold cover to cylinder block 1 DESIGN S N USA D279349 amp BELOW 9793444 amp BELOW DESIGN Ill S N USA D279350 amp UP BEL 9793445 amp UP 90 814676R1 DECEMBER 1996 POWERHEAD 4 7 Crankshaft Pistons and Connecting Rods Loctite 271 Obtain Locally 2 Cycle Outboard Oil 92 13249A24 2 4 C With Teflon 92 825407A12 4 8 POWERHEAD 90 814676R1 DECEMBER 1996 Crankshaft Pistons and Connecting Rods TORQUE QTY DESCRIPTION Ib in Ib ft 1 CRANKSHAFT O RING KEY crankshaft MAIN BEARING ASSEMBLY VALVE TYPE DOWEL PIN main bearing DOWEL PIN reed locating SCREW main bearing NUT main bearing screw REED SET matched REED STOP SC
207. bly also mounted under the fly wheel has 2 coils The flywheel likewise has a se cond set of magnets located around the hub As the flywheel rotates the second set of permanent mag nets passes the trigger coils This causes the trigger coils in turn to produce an AC voltage that is con ducted to an electronic switch SCR in the switch box 90 814676R1 DECEMBER 1996 Red Stator Models e Adapter Module The switch discharges the capacitor voltage into the ignition coil at the correct time and in firing order se quence Capacitor voltage is conducted to the ignition coil pri mary The ignition coil multiplies this voltage to a val ue high enough to jump the gap at the spark plug The preceding sequence occurs once per engine revolution for each cylinder Spark timing is changed advanced retarded by ro tating the trigger coil position in relation to the perma nent magnets on the flywheel hub Red Stator Models Red stators require an adapter module that gets con nected between the stator and switch box Without the adapter module the voltage supplied by the sta tor would exceed the voltage capability of the switch box ELECTRICAL AND IGNITION 2A 1 Ignition Troubleshooting DANGER HIGH VOLTAGE SHOCK HAZARD Do not touch ignition components and or metal test probes while engine is running and or being cranked STAY CLEAR OF SPARK PLUG LEADS To assure personal safety each indi
208. brication of this section see Table of Con tents Refer to Gear Housing Removal and Installation Section 5 1 8 IMPORTANT INFORMATION 90 814676R1 DECEMBER 1996 3 Tilt Lock Lever Grease Fitting 4 Swivel Pin Grease Fittings Ride Guide Steering Cable and Pivot Points Lubrication Core of steering cable transom end must be ful ly retracted into cable housing before lubricating cable If cable is lubricated while extended hy draulic lock of cable could occur With core of Ride Guide Steering cable transom end fully retracted lubricate transom end of steering cable thru grease fitting and exposed portion of cable end with Quicksilver 2 4 C Marine Lubricant Lubri cate all pivot points with SAE 30W engine oil va LS ish R 50334 5 Ride Guide Steering Grease Fitting 6 Tilt Tube Grease Fitting 7 Steering Link Rod Pivot Point Lubrication 90 814676R1 DECEMBER 1996 26474 8 Propeller Shaft Lubrication 12579 9 Starter Motor Pinion Gear Lubrication IMPORTANT INFORMATION 1 9 Gear Housing Lubrication NOTE Refer to Specifications for gear housing lu bricant capacity If gear housing is installed on outboard to avoid accidental starting disconnect and isolate spark plug leads from spark plugs before work ing near the propeller CAUTION Do not use automotive grease in the gear hous ing Use only Quicksilver Gear Lube or Quicksil
209. cap for correct alignment If not aligned a ridge can be seen or felt atthe separating line as shown Correct any misalignment Use a small diameter wire and try to spread needle bearings apart If needle bearings do not spread the width of a single bearing the correct number of bearings has been used Rotate con necting rod after torquing checking that it ro tates freely If rough remove and check race and needle bearings Repeat preceding procedure for remaining con necting rods 90 814676R1 DECEMBER 1996 Piston Installation 1 Place a piece of paper on bench and line up pis ton pin needle bearings CAUTION Never inter mix new needle bearings with used bearings atthe same piston pin end If any needle bearing requires replacement replace all bear ings 2 Place sleeve on Piston Pin Tool 91 76160A2 and apply a small amount of Quicksilver Needle Bearing Assembly Lubricant around sleeve Roll tool over lined up bearings a Piston Pin Tool 91 76160A2 b Sleeve Needle Bearings 27 Required 3 Place lower locating washer on connecting rod and slide sleeve along with needle bearings thru washer and into connecting rod Add needle bearings until race will accept no more 27 re quired 54717 a Sleeve b Locating Washer Needle Bearings 27 Required 90 814676R1 DECEMBER 1996 4 Place upper locating washer over sleeve on pis ton pin tool then slide piston pin tool o
210. ce 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check valve components from trim rod piston a Screw 3 b Plate c O ring d Piston A CAUTION When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to trim piston MID SECTION 5C 23 4 Placetrim rod into soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 5 Loosen trim rod piston using trim spanner ner wrench 1 4 in x 5 16 in long pegs 6 Allow trim rod piston to cool remove from trim rod 51146 a Trim Rod Piston b Spanner Wrench 5C 24 MID SECTION cM A CAUTION Do not remove check ball components from trim rod piston Removal and re installation of check valve could result in improper operating pres sure and possible power trim system damage If check valve is defective replace trim rod piston 7 Remove inner O ring from piston 51199 Check Ball Components O ring Piston oom 8 Remove rod wiper inner O ring and outer O ring 51145 a Rod Wiper b Inner O ring C Outer O ring 90 814676R1 DECEMBER 1996 Trim Motor Removal 1 Secure power trim assembly in soft jawed vise 2 Remove cap washer and grommet from reser voir assembly 51195 Cap Washer Grommet 3 Remove screws securing reservoir cap to reser voir 51193 a Screws
211. center lines Lubricate inside of rubber sleeves with Quicksilver 2 4 C Marine Lubricant and slide sleeves on steering coupler Work rubber bushings onto threaded ends of steer ing eyes Thread jam nut on starboard steering eye Thread steering eyes equally into coupler so that dis tance between hole centers of steering eye ball joints is equal to distance between threaded hole centers of steering arms brackets Exposed threads of steer ing eyes MUST BE of equal length and threads MUST NOT extend out from coupler more than 2 3 4 in 70mm a Coupler b Rubber Sleeve Steering Eye d Rubber Bushing e Jam Nut Both steering eyes must be threaded into cou pler 3 4 in 19mm minimum Thread length of steering eye is 3 1 2 in 89mm so exposed thread must not extend out of coupler more than 2 3 4 in 70mm Failure to adhere to this require ment could result in steering system failure 7 12 OUTBOARD MOTOR INSTALLATION ATTACHMENTS Assemble steering coupler between outboard steer ing brackets as shown on the following pages IMPORTANT With assembled steering coupler installed and before tightening special washer head bolts locknuts check outboard alignment Distance between hole centers of steering eye ball joints MUST BE equal to distance between propeller shaft center lines for proper steering If adjustment is necessary temporarily remove special washer head bolt locknut from one steer
212. cient to refinish several gear housings Procedure 1 Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth and rinse with water if necessary 2 Wash gear housing with soap and water then rinse 90 814676R1 DECEMBER 1996 3 Sand blistered area with 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only Feather edge all broken paint edges 4 Clean gear housing thoroughly with DX 330 wax and grease remover 5 Spot repair surfaces where bare metal is ex posed with DX 503 alodine treatment IMPORTANT Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering 6 Mix epoxy chromate primer DP 40 with equal part catalyst DP 401 per manufacturers instructions allowing proper induction period for permeation of the epoxy primer and catalyst 7 Allow a minimum of one hour drying time and no more than one week before top coating assem blies 8 Use Ditzler Urethane DU9000 for Mercury Black DU34334 for Mariner Grey and DU35466 for Force Charcoal and DU33414M for Sea Ray White Catalyze all three colors with Ditzler DU5 catalyst mixed 1 1 ratio Reduce with solvents per Ditzler label A CAUTION Be sure to comply with instructions on the label for ventilation and respirators Using a spray gun apply one half to one mil even film thick
213. cked at the listed RPM with an in series ammeter Manual Start Stator 90 814676R1 DECEMBER 1996 ELECTRIC START MODELS WITH RECTIFIER a Rectifier b Red Lead IMPORTANT Rectifier must be functioning prop erly for accurate test results to be obtained 1 Remove RED lead from terminal of rectifier 2 Connect RED ammeter lead to rectifier ter minal and BLACK ammeter lead to RED recti fier lead 3 With engine running at the indicated RPM the ammeter should indicate the following approxi mate amperes 9 Amp Black Stator Red Stator Used with Fly wheels having Magnets Installed With Epoxy Red Stator Used with Fly wheels having Magnets Installed With Retaining Ring 4 f proper ampere readings are not obtained re place stator ELECTRICAL AND IGNITION 2B 5 ELECTRIC START MODELS WITH VOLTAGE REG ULATOR RECTIFIER b lt Voltage Regulator Rectifier Red Lead Smaller Diameter Red Larger Diameter 9 Volt Transistor Battery Connect Ammeter Between Red Leads Check battery voltage at battery with engine run ning If battery voltage is above 14 5 volts replace volt age regulator rectifier Check condition of battery as overcharging may have damaged battery If battery voltage is below 14 5 volts charge bat tery If battery can not be satisfactorily charged replace battery If cranking voltage is
214. commended Gasoline Any leaded or unleaded lead free gasoline with a minimum posted octane rating of 86 research octane number 90 Remote Fuel Tank Capacity U S Gallons 6 6 Imperial Gallons 5 5 Liters 25 Quicksilver 2 Cycle Outboard Oil Approximate Running Time Remaining at Wide 30 Minutes Open Throttle when Buzzer Sounds Recommended Battery Rating Minimum Reserve Capacity rating of 100 Minutes and Cold Cranking Amperage of 350 Amperes Specification for Oil Injected Model 1 2 IMPORTANT INFORMATION 90 814676R1 DECEMBER 1996 Q Propeller Selection 1 Select a propeller that will allow the engine to op erate at or near the top of the recommended full throttle RPM range listed in Specifications preceding with a normal load Maximum engine speed RPM for propeller selection exists when boat speed is maximum and trim is minimum for that speed High RPM caused by an excessive trim angle should not be used in determining cor rect propeller Normally there is a 150 350 RPM change between propeller pitches 2 If full throttle operation is below the recom mended range the propeller MUST BE changed to a lower pitch to prevent loss of performance and possible engine damage 3 For better acceleration such as is needed in wa ter skiing propping up to 500 RPM above the rec ommended range is advised Continuous opera tion above the recommended maximum RPM however is not permissible 4 Aft
215. ct Relief P ressure 22 880 1110 40 60 aes A M 1220 1420 75 125 9 f Up Pressure 1625 40 60 Tilt Relief Pressure de 250 400 40 60 540 990 75 125 a Piston Rod m Shuttle Valve b End Cap n Up Pressure Operated Valve c Electric Motor Manifold Reverse Suction Valve d Reservoir Oil p Manual Release Valve e Down Pressure Regulating Valve q Manifold f Down Pressure Operated Valve r Tilt Relief Valve g Filter 2 shown for clarity s Tilt Relief Piston h Shock Return Valve t Memory Piston i Up Circuit Suction Port u Shock Piston Oil Pump v Impact Relief Valve k Down Circuit Suction Port w Cylinder Oil Fill Cap 5E 14 MID SECTION 90 814676R1 DECEMBER 1996 c Shock Function Up Oil inside the down cavity is locked in a static position by the closed pressure operated valve f the manual release valve p and the manifold reverse suction valve o Ifthe outboard strikes an underwater object while in forward gear the piston rod a will try to rap idly extend from the cylinder w the pressure in creases inside the trim cylinder down cavity and con necting passages When the pressure increases to the level required the impact relief valves v located inside the shock piston u will open and allow the fluid to
216. ctory and requires no additional lubrication at initial installation 1 Lubricate inside of outboard tilt tube a and en tire steering cable end b with Quicksilver 2 4 C Marine Lubricant 2 Insert steering cable end thru outboard tilt tube and secure steering cable to tilt tube with steering cable attaching nut c as shown Torque nutto 35 Ib ft 41 3 Place a mark a on tilt tube 1 4 in 6 4mm for port end of tube Slide plastic spacer b O ring c and cap d over steering cable end to tilt tube on outboard 1 4 in 50180 90 814676R1 DECEMBER 1996 Installing Steering Link Rod Steering link rod MUST BE secured between out board steering arm bracket and steering cable end using special washer head bolt P N 10 14000 and two nylon insert locknuts P N 11 34863 as shown Both special washer head bolt and nylon insert locknuts MUST BE tight ened as specified Lubricate hole in end of steering cable with Quicksil ver 2 4 C Marine Lubricant Assemble steering link rod to steering cable end using 2 flat washers and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 14 N m of torque then back nut off 1 4 turn Lubricate ball joint in steering link rod with SAE 30W motor oil Secure link rod to outboard steering arm in ner hole closest to outboard using special washer head bolt P N 10 14000 provided and nylon insert locknut as shown Torque special bolt
217. d Reassembly 5F 30 Shock Rod Installation 5F 32 Instructions for Making Retaining Tool 5F 33 Bleeding Manual Tilt System 5F 34 Manual Tilt System Installation 5F 35 90 814676R1 DECEMBER 1996 2 Manual Tilt System Components Design One and Two 1 Shock Rod Oylind 2 Torque Specification 3 Shock Rod 4 Valve Block 35 lb ft 47 5 Dowel Pin 6 Pivot Pin 9 100 lb in 11 2 N m 7 Rod Wiper 8 O ring 671 in I D 351b in 4 0 10 O ring 1 864 in 1 0 11 O ring 614 in LD 27 Ib in 3 0 12 Shock Rod Piston 13 Ball 5 750 in 8 5 14 Spring Seat 5 15 Spring 5 16 seh Plate Bottom of Valve Block Cylinder 17 Screw 3 18 O ring 1 600 I D Shock Piston 19 O ring 1 600 I D Memory Piston dl 20 Memory Piston 21 Screw 2 tes 22 O ring 208 in 1 0 2 23 Pipe Plug 2 d 25 Spring Small Check m 3 24 Spring Large 26 Ball 2 27 Plunger DESIGN 2 28 Screw Plug 2 3 4 29 Spring 2 30 O ring 2 31 Ball 2 32 Push Rod 2 33 Dowel Pin 34 Spool 35 Spring 36 O ring 301 I D 37 Screw Plug 38 O ring 301 I D 39 Cam Shaft 40 Insulator 41 Retainer Plate 42 Screw 43 O ring 2 114 in 1 0 44 Push Rod 45 Ball 46 Flat Spring 47 Screw Design One Only 48 O ring 49 F
218. d have hull and transom that is de ability to plane See the following table signed for use with a jet drive 1 The boat should be as light as possible 3 The boat should be at least 13 feet in length Engine Horsepower Selection The following table is based on experience obtained with sled type boats using outboard jets The gross weights shown in cludes the outboard boat people and all the gear carried For a given horsepower loading beyond these weights will give less than good performance 500 6 8 1000 12 14 16 18 2000 22 24 26 28 3000 32 34 36 Gross Weight Lbs 6B 4 LOWER UNIT 90 814676R1 DECEMBER 1996 Transom Height of the Boat Outboards with jet drives will be mounted approxi mately 7 inches higher on the transom than propeller driven outboards This requires outboards that have a 15 in shaft length to be installed on boats having a 22 in transom height and outboards that have a 20 in shaft length to be installed on boats having a 27 in transom height If the boat transom is of insufficient height and the outboard cannot be installed to the recommended height contact the boat manufacturer for recom mended procedure to build up the boat transom Locate Centerline Of The Outboard Locate and mark with pencil the vertical centerline of boat transom 0 a Centerline of Transom Outboard Mounting Height The initial outboard mounting height setting will work good fo
219. del 40 Electric Start with 16 Amp Red Stator 2D 7 Wiring Diagram Model 40 Electric Start Tiller Handle with 16 Amp Black Stator 20 8 Wiring Diagram Model 40 Electric Start Tiller Handle with 16 Amp Red Stator 2D 9 Wiring Diagram Model 40 Manual Start with Black Stator 2D 10 Wiring Diagram Model 40 Manual Start with Red Stator 2D 11 Power Trim Wiring Diagram 2D 12 Commander 2000 Side Mount Remote Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram 2D 13 Commander 2000 Side Mount Remote Control Electric Start with Warning Horn Wiring Diagram 20 14 Commander 2000 Side Mount Remote Control Manual Wiring Diagram 2D 15 Key Choke Switch Continuity Test Commander 2000 Side Mount Remote Control 2D 16 Panel Mount Remote Control Wiring Diagram 20 17 Remote Key Switch and Warning Horn 2D 18 2D 0 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 aX Wiring Diagram Model 30 Jet with 16 Amp Black Stator BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT BLU LIGHT BLUE Stator Trigger Starter Starter Solenoid Voltage Regulator Rectifier Battery Engine Harness
220. drive shaft from gear housing 54771 Forward Gear Drive Shaft Pinion Gear Pinion Nut Hidden Flat Side Away from Pinion Gear Remove pinion gear and forward gear assembly from housing 90 814676R1 DECEMBER 1996 5 Iftapered drive shaft bearing is rusted or does not roll freely or if race is damaged replace bearing and race as an assembly Universal Puller Plate 91 37241 Press Tapered Bearing 6 Remove bearing race using slide hammer 54773 a Race b Shim s Slide Hammer 91 34569 1 90 814676R1 DECEMBER 1996 Lubrication Sleeve Removal 1 Remove lubrication sleeve using puller Puller 91 27780 b Lubrication Sleeve 54774 LOWER UNIT 6A 11 Forward Gear and Bearing Removal 1 Iftapered forward gear bearing is rusted or does not roll freely or if race is damaged replace bear ing and race as an assembly 2 Remove bearing as shown Ses E Universal Puller Plate 91 37241 Mandrel 36569 Bearing Press 54775 3 Remove race using slide
221. e Wet application will allow time to position de cal Read entire installation instructions on this technique before proceeding TEMPERATURE IMPORTANT Installation of vinyl decals should not be attempted while in direct sunlight Air and surface temperature should be between 60 F 15 C and 100 F 38 C for best application SURFACE PREPARATION IMPORTANT Do not use a soap or any petroleum based solvents to clean application surface Clean entire application surface with mild dish wash ing liquid and water Rinse surface thoroughly with clean water 1 18 IMPORTANT INFORMATION DECAL APPLICATION 1 Mix 1 2 ounce 16 ml of dish washing liquid in one gallon 4 of cool water to use as wetting solu tion NOTE Leave protective masking if present on the face of decal until final steps of decal installation This will ensure that the vinyl decal keeps it s shape during installation 2 Place the decal face down on a clean work sur face and remove the paper backing from adhe sive side of decal 3 Using a spray bottle flood the entire adhesive side ofthe decal with the pre mixed wetting solu tion 4 Flood area where the decal will be positioned with wetting solution 5 Position pre wetted decal on wetted surface and slide into position 6 Starting at the center of the decal lightly squeegee out the air bubbles and wetting solu tion with overlapping strokes to the outer edge of t
222. e outlet tube located in fuel tank Problem Fuel Blow Back Out of Carburetor Chipped broken reed block reeds Replace reeds 90 814676R1 DECEMBER 1996 Problem Rough Idle Possible Cause Corrective Action If related to reed block in Replace reeds dicates excessive preload in reeds Problem Can t Reduce Engine RPM to Slow Idle Possible Cause Corrective Action Multiple chipped reeds Replace reeds Checking for Restricted Fuel Flow Caused by Anti Siphon Valves Refer to Fuel Pump General Information for troubleshooting procedures page 4 Carburetor Adjustments Initial Starting Adjustment 1 After service or replacement of carburetor turn idle mixture screw adjustment in clockwise until it seats LIGHTLY then back off each carbure tor 1 1 4 turns This will permit engine startup Idle Speed Adjustment 1 Adjust engine idle RPM as outlined in Section 2C Timing Synchronizing Adjusting FUEL SYSTEM AND CARBURETION 3 13 Idle Mixture Screw Adjustment 1 Place outboard in test tank or place boat and out board in water 2 Preset carburetor idle mixture screw at 1 1 4 turns out from lightly seated position 52020 3 Startoutboard and allow to warm up to operating temperature 4 Place outboard in gear with engine running Slowly turn idle mixture screw counter clockwise until the corresponding cylinders start to load up or fire unevenly due to an over ric
223. e and hu of fixed jet as shown Replace float if measure midity and or elevation may result in a too lean or ment is not obtained rich fuel mixture at wide open throttle which may re quire a change in the high speed jet A smaller size main jet will lean the fuel mixture and a larger size jet will richen the fuel mixture WMATB Carburetor a Float Bottom b Fixed Jet FLOAT LEVEL WMA9 CARBURETOR 1 9 carburetors adjust float level to 11 16 in 17 46mm from float bottom to casting 52015 a Main Jet WMA9 Carburetor FLOAT DROP WMA9 CARBURETOR ONLY Float drop is not adjustable on WMA9 carburetors 52026 90 814676R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 15 Vent Jet The vent jet supplies less than atmosphere pressure to the fuel bowl at mid range which results in im proved fuel economy If a jet with a larger orifice is in stalled or jet is removed the mid range fuel air ratio will be richer a Vent Jet c High Altitude Jetting The carburetor jets installed at the manufacturer is for outboard operation at sea level through an eleva tion of 2500 feet 762m above sea level If the out board is to be operated at an altitude higher than 2500 feet it will be necessary to rejet remove the carburetor jet and install jet with a different orifice size the carburetor Each time the engine is to be op erated at a different elevation refe
224. e charged at any rate in am peres as long as spewing of electrolyte from vi olent gassing does not occur and as long as electrolyte temperature does not exceed 125 F 52 C If spewing of electrolyte occurs or if elec trolyte temperature exceeds 125 F charging rate in amperes must be reduced or temporarily halted to avoid damage to the battery 2 Battery is fully charged when over a 2 hour peri od at a low charging rate in amperes all cells are gassing freely not spewing liquid electro lyte and no change in specific gravity occurs Full charge specific gravity is 1 260 1 275 cor rected for electrolyte temperature with electrolyte level at 3 16 4 8mm over plate unless electro lyte loss has occurred from age or over filling in which case specific gravity reading will be lower For most satisfactory charging lower charging rates in amperes are recommended 90 814676R1 DECEMBER 1996 c i 3 If after prolonged charging specific gravity of at least 1 230 on all cells cannot be reached battery is not in optimum condition and will not provide optimum performance however it may continue to provide additional service if it has performed satisfactorily in the past 4 To check battery voltage while cranking engine with electric starting motor place red lead to tester on positive battery terminal and black lead of tester on negative battery terminal If the voltage drops below 9 1
225. e memory piston t clears or un covers the pressure relief passage Oil from the up cavity will enter this passage and if required causes the tilt relief piston s to open the tilt pressure relief valve r This valve lowers the amount of pressure available to lift the outboard motor With the engine in forward gear and at high engine rpm the oil pres sure available will not be able to overcome the pro peller thrust limiting the trim range to below the pres sure relief orifice When the engine rpm s fall or if engine is not in forward gear the oil pressure is avail able to extend the piston rod a up into the tilt range 90 814676R1 DECEMBER 1996 MID SECTION 9 V e 1 Up Pressure 1625 40 60 2800 75 125 min a Piston Rod b End Cap c Electric Motor d Reservoir Oil e Down Pressure Regulating Valve f Down Pressure Operated Valve g Filter 2 shown for clarity h Shock Return Valve i Up Circuit Suction Port Oil Pump k Down Circuit Suction Port Oil Fill Cap 5E 10 MID SECTION r Tilt Relief Press 134 250 400 40 60 540 990 75 125 m Shuttle Valve n Up Pressure Oper
226. e of receptacle Holding engine throttle lever e against idle stop adjust throttle cable barrel f to slip into upper hole of barrel receptacle with a very light preload of throttle lever against idle stop A NEG r 2 505640 50564D Position barrel receptacle back down into recess of bottom cowl and lock receptacle in place with barrel retainer g Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be re moved without tearing but has some drag on it Readjust cable barrel if necessary 90 814676R1 DECEMBER 1996 Connecting Remote Control Wiring Harness to Engine Wiring Harness Electric Start Models Route remote control harness or key switch harness down side of boat to engine fastening harness to boat Be sure that harness does not rub get pinched or come in contact with bilge water Route the remote control wiring harness a into bot tom cowl thru control cable grommet Route harness behind oil tank to engine harness connector located on starboard side of engine 919 H 90 814676R1 DECEMBER 1996 Plug remote control wiring harness into engine har ness connector b and push connection into retainer 50566 A CAUTION Remote control wiring harness or key switch wir ing harness must be routed between control cable rubber grommet and engine attachment points so
227. e thoroughly with hot water A good cleaning is essential If any of the abrasive material is allowed to remain in the cylinder bore it will cause rapid wear of new piston rings cylinder bore and bearings After cleaning bores should be swabbed several times with engine oil and a clean cloth then wiped with a clean dry cloth Cyl inders SHOULD NOT be cleaned with kero sene or gasoline Clean remainder of cylinder block to remove excess material spread dur ing honing operating 2 Hone all cylinder walls JUST ENOUGH to de glaze walls 3 Measure cylinder bore diameter with an inside micrometer of each cylinder Check for tapered out of round egg shaped and oversized bore a Inside Micrometer POWERHEAD 4 25 Cylinder Bore Size Cylinder Bore Finish Hone With Standard Size Piston With 015 Oversize Piston With 030 Oversize Piston 2 565 65 15mm 2 580 65 53mm 2 595 65 91mm 1 If cylinder bore is tapered out of round or worn more than 004 0 10mm from STANDARD PISTON DIAMETERS and CYLINDER BLOCK FINISH refer to chart preceding it will be necessary to re bore cylinders to 015 0 38mm or 030 0 762mm oversize and install oversize piston s and piston rings during reassembly If 030 oversize cylinder block finish hone diameter is tapered out of round or worn more than 004 cylinder block must be replaced NOTE The weight of an oversize piston
228. ease valve Replace manual re Trim will not hold lease valve and O reverse thrust Trim system holds reverse thrust Test ing complete rings Trim system holds Remove and inspect pis reverse thrust Test ton rod assembly for de Shock piston appears O K ing complete bris and or shock ball Clean and reinstall piston hang up rod assembly Debris and or shock ball hang up identi Trim will not hold 1 reverse thrust Trim system holds reverse thrust Test Replace piston ing complete rod assembly Remove PO check valve assembly inspect O rings and seals for damage Trim system holds reverse thrust Test ing complete Debris and or dam PO check valve appears age identified O K Clean and reinstall PO check valve assembly Replace PO check valve assembly Trim system holds reverse thrust Test ing complete Trim will not hold Trim system holds reverse thrust reverse thrust Test ing complete continued on next page 90 814676R1 DECEMBER 1996 MID SECTION 5E 21 cM Hydraulic System Troubleshooting Flow Chart continued Remove suction seat as sembly and inspect for debris and or damage Suction seat assembly ap pears O K Clean and rein stall suction seat assembly Replace suction seat P assembly Trim will not hold reverse thrust Trim system holds reverse thrust Test ing complete Debris and or damage identified Trim system holds reverse
229. eck oil level in oil tank 2 Make sure a remote gasoline and oil mixture of 50 1 is used during the initial break in of the en gine or after extended storage 3 Becertain the warning horn is operational Each time the key switch is turned from the off to on position engine not running the warning horn will sound momentarily This tells you the warning system is functional and the warning horn is opera tional If warning horn does not sound or horn stays on when key is turned to the ON position refer to oil injection system troubleshooting chart following to correct the problem The oil injection warning sound is an intermittent etc The overheat warning sound is a continuous beep not intermittent Check Operation of the Oil Injection System Engine Running 1 Operate engine following the break in procedure outlined in the Operation and Maintenance Manual If warning horn should sound an inter mittent during operation this indicates a problem occurred in the oil injec tion system Refer to troubleshooting following to correct the problem 8 6 OIL INJECTION SYSTEM c CE Required Side Mount Remote Control or Ignition Key Switch Assembly to be Used with Engines Equipped with Oil Injection BOATS EQUIPPED WITH A SIDE MOUNT REMOTE CONTROL A Quicksilver Commander Series Side Mount Re mote Control equipped with a warning hor
230. eck water passages for obstructions Bearings BALL ROLLER BEARINGS 54779 A CAUTION DO NOT spin dry ball roller bearings with com pressed air 1 Clean bearing in solvent and dry with com pressed air 90 814676R1 DECEMBER 1996 LOWER UNIT 6A 13 Bearing should be free of rust stains 3 Attempt to work inner bearing race in and out There should not be excessive play Lubricate bearing with Quicksilver Gear Lube Rotate inner bearing race Bearing should have smooth action If ball bearing sounds or feels rough or has catches remove and discard bear ing Refer to Disassembly preceding 54781 NEEDLE BEARING 1 Clean needle bearings in solvent and dry with compressed air replace bearing if needles are rusted fractured worn galled discolored or if area of shaft that bearing contact is worn or pitted 54782 6A 14 LOWER UNIT cM Replace propeller shaft if any of the following conditions exist Propeller Shaft a Splines are twisted or worn b Oil Seal surfaces are deeply grooved allow ing water to enter gear housing Sliding clutch slot worn Bearing surface is pitted worn rusted or contain imbedded metal particles oe 54783 2 Check propeller shaft for straightness Place shaft on either balance wheels or V blocks and rotate shaft while observing spline area for bend wobble If movement recorded is more than 006 in 152mm re
231. ect length of steering cable and remote con trol cables IMPORTANT Steering cable and remote control cables must be the correct length sharp bends on too short cables result in kinks too long cable require unnecessary bends and or loops Both conditions place extra stress on the cables Install steering mount and steering wheel in accor dance with installation instructions that accompany each Installing Ride Guide Cable to Outboard Tilt Tube IMPORTANT Before installing steering cable into tilt tube lubricate entire cable end with Quicksilver 2 4 C Marine Lubricant NOTE Ride Guide Steering cable is lubricated at the factory and requires no additional lubrication at initial installation 1 Lubricate inside of outboard tilt tube a and en tire steering cable end b with Quicksilver 2 4 C Marine Lubricant 2 Insert steering cable end thru outboard tilt tube and secure steering cable to tilttube with steering cable attaching nut c as shown Torque nutto 35 Ib ft 41 N m 90 814676R1 DECEMBER 1996 3 Place a mark a on tilt tube 1 4 in 6 4mm from port end of tube Slide plastic spacer b O ring c and cap d over steering cable end to tilt tube on outboard 1 4 in Installing Steering Link Rod Steering link rod MUST BE secured between out board steering arm bracket and steering cable end using special washer head bolt P N 10 14000 and two nylon insert locknuts P N 11 3486
232. ed replace mercury switch x Ve 54638 a Red Ohm Lead b Black Ohm Lead c Mercury Switch ELECTRICAL AND IGNITION 24 13 PAS Flywheel Removal and 2 Usestrap wrench to hold flywheel while removing flywheel nut and washer Installation Flywheel Removal A CAUTION To prevent accidental starting of outboard while removing engine components on electric start models remove engine battery cables from bat tery and verify ignition key is in the OFF posi tion When servicing manual start engines verify lanyard switch is in the OFF position MANUAL START MODEL 1 Remove 3 bolts securing rewind starter and re move rewind from outboard a Strap Wrench b Flywheel ELECTRIC START MODEL 1 Remove 3 bolts securing flywheel cover and re move cover from outboard a Rewind Starter AN b Flywheel Cover r 54640 a Bolts 2A 14 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 N 2 Use flywheel holder 91 52344 to hold flywheel while removing flywheel nut and washer 54641 a Flywheel Holder 91 52344 b Flywheel NOTE Use flywheel puller 91 73687A1 on both manual and electric start type flywheel Always ins
233. ed Dealer or whenever steering compo nents are disassembled steering effort has in creased or steering seems loose OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 17 Steering Cable Installation 1 on Lubricate steering cable end with Quicksilver 2 4 C Marine Lubricant Install steering cable thru steering cable tube and secure to cable tube with cable attaching nut See below Do not tighten cable attaching nut at this time Attach Ride Guide cable to outboard steering bracket middle hole using Clevis Kit P N 70599A4 Adjust 2 large jam nuts on cable tube of attaching kit so that steering wheel is in normal straight driving position with outboard in straight running position Torque each jam nut to 35 Ib ft 41 5 N m then bend a side of tab washer against flat of each jam nut below m a T 8 cc EINER FI 3 E C MINUS I Leg gt N e Ride Guide Cable Ride Guide Yoke Pivot Block Pivot Spacer 15 in Centerline of Attaching Kit Pivot to Centerline of Engine Pivot Attaching Locknut Torque to 20 Ib ft 27 1 N m Engine Steering Arm h Clevis Kit o3 3 7x Ride Guide Cable Attaching Locknut Torque to 10 Ib ft 13 6 N m Bolt 3 8 in x 2 1 2 in Flat Washer Transom Bracket Cable Tube Jam Nut Torque to 35
234. ed blocks with lo cating pins and push centermain bearing and reed blocks downward to seat them in cylinder block 54728 a Align Centermain Bearing Support and Reed Blocks with Locating Pins and Push Downward to Seat 7 Checkeach piston ring for spring tension thru the exhaust ports by pressing with a screwdriver If no spring tension exists ring fails to return to position it is likely that the piston ring was bro ken during assembly replace broken piston ring s Use caution not to burr piston or ring dur ing inspection 54729 Screwdriver Piston Rings m POWERHEAD 4 41 8 Slide oil pump drive gear onto crankshaft Cham fer side of gear goes towards bottom crankshaft throw Engage key with slot in gear gt pur Su 54730 a Oil Pump Drive Gear b Chamfer c Key d Slot 9 Use a powerhead stand and rotate crankshaft several times to assure free operation no binds and or catches 10 Check crankshaft end play as follows a install upper and lower end caps with original shim s Secure each end cap to cylinder block with end cap bolts b Usea mallet and tap crankshaft toward bot tom stud end of cylinder block Hold crank shaft tight against lower end cap while mak ing measurement in Step C 4 42 POWERHEAD
235. ed cooling system 7 Combustion chamber piston deposits result in higher compression ratio IMPORTANT INFORMATION 1 15 Detonation usually be prevented provided that 1 the engine is correctly set up and 2 diligent main tenance is applied to combat the detonation causes listed preceding 54635 Damaged Piston Resulting From Detonation Compression Check 1 Remove spark plugs 2 Install compression gauge in spark plug hole 3 Hold throttle plates at W O T 4 Crank engine thru at least 4 compression strokes to obtain highest possible reading 5 Check record compression of each cylinder Variation of more than 15 105 per sq in 103 5 kPa between cylinders indicates that lower com pression cylinder is in some way defective such as worn or sticking piston rings and or scored pis ton and cylinder 1 16 IMPORTANT INFORMATION Compression check is important because gine with low or uneven compression cannot be tuned successfully to give peak performance It is essential therefore that improper compres sion be corrected before proceeding with an en gine tuneup Cylinder scoring If powerhead shows any indica tion of overheating such as discolored or scorched paint remove transfer port cover and visually inspect cylinders for scoring or other damage as outlined in Section 4 Power Head
236. ent Vent Jet High Altitude 0 Carburetor Jet Sizes WMA7B Carburetor Jet Orifice Sizes 9 3 16 3 16 cM Page Enrichment System Electric Start Models 3 17 Enrichener Hose Routed to Carburetor Flanges 35 55 KORR NER 3 17 Enrichener Hose Routed to Balance TUDE 3 17 Primer System 3 18 Hose 1 lt 3 18 Enrichener Valve Manual Operation 3 18 Enrichment Valve Test 3 19 Enrichener Valve Replacement 3 19 Fuel Line and Primer Bulb Assembly 3 20 Maintenance 3 20 Fuel Line Clamp Removal Installation 3 20 Carburetor Removal Manual Start Model Pu o rake ba 3 21 Carburetor Disassembly Top Carburetor 3 21 Cleaning and 3 25 Carburetor Reassembly 3 26 Carburetor Installation 3 30 90 814676R1 DECEMBER 1996 Q Specifications Idle RPM In Forward Gear 500 600 Float Level Carb Model WMA7B 1 4 in 1 64 in 6 4mm 0 4mm Carb Model WMA9 11 16 in 1 64 in 16 3mm 0 4mm Float Drop Carb Model WMA7B 1 32 in to 1 16 in 0 80mm to 1 6mm Carb Model WMA9 No Adjustment Special Tools Description Carburetor Scale 91 36392 90 8146
237. ents in place using screwdriver as shown Connect manifold to trim cylinder 54748 90 814676R1 DECEMBER 1996 4 Secure manifold to cylinder using screws torque to 100 Ib in 11 2 N m 54746 a Trim Cylinder b Manifold c Screw Oil Pump Installation 1 Secure power trim unit in soft jawed vise N Install lubricated O rings to manifold Install oil pump to manifold and secure using screw torque to 90 Ib in 10 2 N m 54747 O ring b Oil Pump c Screw MID SECTION 5B 31 Trim Motor Reassembly 3 Align scribe mark on housing with mark on end frame 1 Apply Quicksilver Marine Lubricant 2 4 C to ar mature shaft and insert into end frame 4 Install lubricated O ring to end frame A sAm RESH N DPA 51195 a Armature Shaft b Washer c Frame 51194 a O ring b Scribe Mark 2 Guide armature and end frame into housing as shown 5 Install washers to armature shaft as shown 6 Install end cap to housing Torque nuts to 25 Ib in 2 8 N m End Cap Motor Housing Wave Washer Washer 51196 Qoo v 5B 32 MID SECTION 90 814676R1 DECEMBER 1996 i IMPORTANT When installing motor wires 3 Install end cap O ring and foam pad to cylinder black orange must rest in cavity of cylinder al 4 Torque screws to 13 Ib ft 1 5 N m lowing motor to seat properly a Manifold b Cavity 511
238. er c Propeller Nut Flo Torq Il Drive Hub Propellers 4 an b a Forward Thrust Hub Replaceable Drive Sleeve Rear Thrust Hub Propeller Nut Retainer Propeller Nut Tighten propeller nut to 55 Ib ft 75 Bend tabs against nut Propeller Nut Torque 55 Ib ft 75 N m b Bend Tabs Against Nut IMPORTANT INFORMATION 1 3 Trim In Angle Adjustment Operating some boats with outboard trimmed to the full in trim angle not using trim adjustment bolt a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after outboard installation and after any trim ad justments IMPORTANT Some boat outboard combina tions that do not use the trim adjustment pin a andare trimmed to the full trim angle will not experience any undesirable and or unsafe steer ing conditions during planing speed Thus not using trim adjustment pin may be desired How ever some boats with outboard trimmed to the full In trim angle at planing speeds will cause undesirable and or unsafe steering conditions If these steering conditions are experienced un der no circumstances should the outboard be operated without the trim adjustment pin and without the pin adjusted in the proper holes to prevent unsafe handling characteristics Water test the boat not using the trim adj
239. er initial propeller installation the following common conditions may require that the propel ler be changed to a lower pitch a Warmer weather and great humidity will cause an RPM loss b Operating in a higher elevation causes an RPM loss c Operating with a damaged propeller or a dirty boat bottom or gear housing will cause an RPM loss d Operation with an increased load additional passengers equipment pulling skiers etc Propeller Installation If the propeller shaft is rotated while the engine is in gear there is the possibility that the engine will crank over and start To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating pro peller always shift outboard to neutral position and remove spark plug leads when you are serv icing the propeller 90 814676R1 DECEMBER 1996 Coat the propeller shaft with Quicksilver Anti Corro sion Grease or 2 4 C Marine Lubricant with Teflon IMPORTANT To prevent the propeller hub from corroding and seizing to the propeller shaft es pecially in salt water always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed Flo Torq Drive Hub Propellers c b 1 a Forward Thrust Hub b Propeller Nut Retain
240. er manifold assembly into soft jawed A CAUTION vise mE End cap must not make contact with shock rod 2 Fill cylinder to top using Quicksilver Power Trim piston when tightening Shock rod piston must and Steering Fluid or ATF Type F FA of Dexron be positioned in cylinder deep enough to avoid contact 3 Place cam shaft lever in the open position lever 7 Tighten end cap securely using spanner wrench facing down 1 4 in x 5 16 in 6 4mm x 8mm long pegs 4 Install lubricated O ring to memory piston and in stall piston into cylinder three inches 76mm from top 51145 51144 a O ring b Memory Piston 5 Refill cylinder to top and install shock rod assem bly into cylinder 51143 5F 32 MID SECTION 90 814676R1 DECEMBER 1996 Instructions for Making Retaining Tool 3 16 in x 3 in 5 x 7 5 cm Steel Plate 3 8 in x 13 in 10mm x 33cm Threaded Rod 4 in x 1 4 in min 10cm x 6 4mm minimum Channel Iron 2 holes 7 16 in dia 11 mm 5 in 1 1 4 in dia 125mm 3 30m 20 in 508mm 6 in 8 3 8 in 2 holes 152mm 203mm 90 814676R1 DECEMBER 1996 MID SECTION 5F 33 Bleeding Manual Tilt System IMPORTANT While bleeding tilt system time must be allowed between each stroke to allow air bubbles to dissipate 1 With shock rod in the full up position and manifold cam lever open facing down secure tilt system
241. espective hole 51148 Lower Pivot Pin Lower Dowel Pin 3 Position trim cylinder assembly Bottom First be tween clamp brackets a Trim Cylinder Assembly MID SECTION 5E 43 4 Apply 2 4 C Marine Lubricant 92 90018 12 to lower pivot pin Using a suitable punch drive low er pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside sur face 51147 a Lower Pivot Pin 5 Using a suitable punch drive lower dowel pin into its hole until seated a Lower Dowel Pin 5E 44 MID SECTION 6 Apply 2 4 Marine Lubricant 92 90018 12 to surface of upper pivot pin pivot pin bore and trim ram bore 51148 a Pivot Pin b Pivot Pin Bore c Trim Ram Bore 7 Usinga suitable mallet drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket a Pivot Pin b Swivel Bracket C Trim Ram 90 814676R1 DECEMBER 1996 p i 8 Drive trilobe pin a into its hole until seated a Trilobe Pin 9 Install sacrificial aluminum anode to reservoir bracket placing ground strap between bracket and anode as shown a Sacrificial Anode b Ground Strap Bracket 90 814676R1 DECEMBER 1996 10 Route trim harness through clamp bracket and cowling 55264 a
242. essary IMPORTANT Replace reeds in sets only DO NOT turn used reed over for re use 7 Measuring from top of closed reed to inside of reed stop check reed stop opening of each reed stop Specified reed stop opening is 5 32 3 97mm If reed stop opening is not correct carefully bend reed stop to achieve specified opening 8 After installing any new reeds and having torqued reed retaining screws to 30 in 3 3 N m check new reeds as outlined in Step 5 pre ceding IMPORTANT If engine shows indications of hav ing been overheated check condition of nylon locating pins Damaged melted locating pins Will affect engine operation poor idle hard start ing etc 0 9121 8 v 4 8 1216 20 2428 gg 0291218 v 8 1216 20 2428 4 54707 Top of Closed Reed Inside of Reed Stop Reed Stop Opening 5 32 3 97mm Locating Pins Reed Retaining Screws Torque to 30 Ib in 3 3 N m POWERHEAD 4 27 Connecting Rods 1 Check connecting rod for alignment by placing rods on a surface plate If light can be seen under any portion of machined surfaces if rod has a slight wobble on plate or if a 002 feeler gauge can be inserted between any machined surface and surface plate rod is bent and must be dis carded Feeler Gauge Surface Plate Even Downward Pressure Oo m m Carefully inspect connecting rod bea
243. ey in the START position and held in the valve is opened allowing not only fuel to be gravity fed but also drawn into the engine thru both top and bottom carburetor flanges during each engine revolution When the key is released from the pushed in posi tion the valve will return closed The valve can be op erated manually if valve fails to operate electrically refer to Manual Operation of Enrichener Valve following 90 814676R1 DECEMBER 1996 Enrichener Hose Routed to Balance Tube 50571 Description The enrichener system using enrichener hose routed to balance tube is similar to the system using the enri chener hose routed to the carburetors in that each uses the same electrically actuated valve that can be used manually Although with the key in the RUN position and pushed in and held in the fuel is gravity fed from the top carburetor float bowl directly to the crankcase fuel is dispensed thru internal passages to the bottom two cylinders thru the balance tube lo cated on the starboard side of the outboard With the key in the START position fuel is not only gravity fed to the crankcase bottom two cylinders but also drawn into the crankcase top two cylinders during each engine revolution FUEL SYSTEM AND CARBURETION 3 17 Primer System Hose Installation 50571 Description The primer system consists of a primer bulb that pulls fuel directly from the top carburetor float bowl and de li
244. f barrel receptacle and position receptacle back down into recess Place hole in end of shift cable guide over peg of shift actuator and secure with cable retainer g Le 2 eu ELIT FAN f a s g 7 Check shift cable adjustment as follows a Shift remote control into forward gear Now check prop shaft the shaft should not be able to turn counterclockwise If it does adjust cable barrel closer to cable end guide b Shift remote control into neutral The prop shaft now should turn freely without drag If not adjust cable barrel away from cable end guide Repeat steps a and b c Shift remote control into reverse as the prop shaft is rotated by hand The prop shaft should not be able to turn clockwise If it does adjust cable barrel away from cable end guide Repeat steps a thru c d Shift remote control into neutral The prop shaft should turn freely without drag If not adjust cable barrel closer to cable end guide Repeat steps a thru d 7 20 OUTBOARD MOTOR INSTALLATION ATTACHMENTS p i Throttle Cable Installation and Adjustment to Engine 1 2 Shift remote control into neutral Route throttle cable a thru control cable grom met b Place hole in end of throttle cable end guide over peg of throttle lever and secure with cable retain er c Lift barrel receptacle d out of recess in bottom cowl to allow installation of throttle cable barrel into upper hol
245. fer to Section 8 Oil Injection System 90 814676R1 DECEMBER 1996 POWERHEAD Lj A LJ acu Table of Contents Page Specifications 4 1 Special Tools 4 1 General Information 4 1 Throttle Control 4 2 Cylinder Block and Crankcase Assembly 4 4 End Caps and Exhaust 4 6 Crankshaft Pistons and Connecting Rods 4 8 Powerhead Torque Sequence and Torque Specifications 4 10 Powerhead Removal from Driveshaft HOUSING ia se ERES Ee ARR d RUE 4 11 Electric Start Model 4 11 Manual Start Model 4 14 Powerhead Disassembly 4 16 End Cap Disassembly 4 21 Crankshaft Disassembly 4 22 Cleaning and Inspection 4 25 Cylinder Block and Crankcase 4 25 Cylinder Bore Cleaning and 5 4 25 Honing Procedure 4 25 Cylinder Bore Size 4 26 PISIOIS rods xa Re ek ax Rd an 4 26 Measuring Piston Roundness 4 27 Reed Blocks 4 27 Connecting Rods
246. ffee can could be used 2 Fill container to near full level using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid IMPORTANT Fluid level must remain above ac cumulator opening during bleeding process 4 During up stroke pull up on rod slowly 3 in 76mm from base 5 Wait until all air bubbles exit accumulator base 50447 Retaining Tool Tilt System Container Cam Lever Accumulator Opening 6 Slowly cycle unit 5 8 times round trip per cycle using short strokes 3 in 76mm from base allow ing bubbles to disappear during each stroke 5G 32 MID SECTION 90 814676R1 DECEMBER 1996 A 14 7 Allow unit to stand five minutes then proceed to 11 With cam lever remaining open facing down re cycle unit 2 3 more times using short strokes No move tilt assembly from oil and secure in soft air bubbles should appear from accumulator port jawed vise Torque accumulator to 35 Ib ft 47 at this time N m 8 With oil level well above accumulator port slowly pull rod to full up position 9 Install accumulator making sure air bubbles do not enter system 10 Tighten accumulator snugly at this time 50432 90 814676R1 DECEMBER 1996 MID SECTION 5G 33 Manual Tilt System Installation 1 Apply
247. four screws securing reservoir to man Oil Pump Removal ifold IMPORTANT The oil pump is not rebuildable If oil pump is defective replace as an assembly 1 Remove screw oil pump and O rings from man ifold a Screw 4 Remove reservoir from manifold 5 Remove drive shaft from oil pump a O ring b Oil Pump Screw Manifold Removal 1 While holding trim cylinder to manifold remove screws a Drive Shaft b Oil Pump 51007 a Trim Cylinder b Manifold c Screw 90 814676R1 DECEMBER 1996 MID SECTION 5B 27 2 Slowly remove manifold from cylinder Note posi tion of above trim check ball assembly and re move 54744 a Above Trim Check Ball Components 5B 28 MID SECTION cM 3 Remove O rings from cylinder 4 Remove filter a O rings b Filter Cleaning and Inspection of Trim Rod Components IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction CAUTION Do not remove check valve components from trim rod piston Removal and reinstallation of check valve could result in improper operating pressure and possible power trim system dam age 51199 a Check Ball Components 90 814676R1 DECEMBER 1996 Q Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace trim rod piston as a
248. ft and other lead on commutator 2 If meter indicates continuity armature is grounded and must be replaced 11675 Armature Test for Ground Bosch 90 814676R1 DECEMBER 1996 cM Checking Positive Brushes and Terminal Set VOA meter to R x 1 scale Connect meter leads between positive brushes Meter must indicate full continuity or zero resistance If resistance is indi cated check lead to brush and lead to positive termi nal solder connection If connection cannot be re paired brushes must be replace sank a tes t no lt t 11673 a Positive Brushes 90 814676R1 DECEMBER 1996 Testing Negative Brushes for Ground Bosch Set VOA meter to R x 1 scale Place one lead of the VOA on the negative brush and the other lead on the end cap bare metal If the meter indicates NO conti nuity replace the negative brush Repeat this proce dure on the other negative brush lt Sean 2 5 11674 Negative Brushes b End Cap ELECTRICAL AND IGNITION 2B 13 Reassembly 1 If brushes were removed replace as follows a Install positive brushes along with positive terminals into commutator end cap Positive Brushes Components 54656 Insulating Bushing Positive Terminal Insulating Washer Flat Washer Lockwasher Hex Nut 2B 14 ELECTRICAL AN
249. g 90 814676R1 DECEMBER 1996 Torque Specifications Q 20 Ib ft 27 9 40 Ib ft 54 2 Torque until it seats then back off 1 4 turn Quicksilver Lubricants and Service Aids 2 4 C Marine Lubricant See Quicksilver Accessories Guide for part number MID SECTION 5A 1 Transom Bracket Torque Specifications Components 60 Ib in 6 8 N m Transom Bracket 2 25 Ib ft 9 Tilt Tube 1 MU Cap Nylon O ring Spacer Quicksilver Lubricants and Service Lock Nut 2 i Washer 2 Tilt Lock L ilt Lock Lever E gt 2 4 Marine Lubricant Spring 3 5 ee Quicksilver Accessories Guide for partnumber 12 Spring 13 Lever 14 Roll P in 15 GreaseFitting 16 Bolt 6 17 Lock Washer 4 18 Lock Nut 2 19 Bolt 4 20 Washer 4 21 Nut 4 22 Trim Adjustment P in 23 Clamp 24 Washer 25 Bolt 26 Lower Mounting Bracket 27 Anode Plate 28 Washer 2 29 Bolt 2 Manual Tilt Models Only 30 Link 31 Bolt 32 Spring Washer 33 Tilt Lever 34 Grip Rubber 35 Washer Outboard Mounting Assembly 36 Bolt 2 37 T handle 2 38 Bolt 4 39 Washer 8 40 Bracket 8 41 Nut 4 OO O Ul 50373 5A 2 MID SECTION 90 814676R1 DECEMBER 1996 rive Shaft Housing Components Drive Shaft Housing Stud Plug Stud Nut 8 Washer 2 Nut 2 M
250. g Black Ground Wire Starter Motor Solenoid Ground h Lower Mounting Clamp 2B 10 ELECTRICAL AND IGNITION 1 Install collars on starter motor if removed Installation 2 Connect BLACK ground cable to starter using bolt and lockwasher if removed Torque boltto 85 Ib in 9 6 a Collars b Black Ground Cable 3 Install starter motor to outboard using upper and lower mounting clamps and four mounting bolts Secure BLACK ground cables and BLACK ground wire under heads of mounting bolts Torque bolts to 180 Ib in 20 3 N m 4 Connect BLACK positive cable to starter mo tor Torque nut to 70 Ib in 7 9 N m 90 814676R1 DECEMBER 1996 Bosch Starter Disassembly 1 Remove starter as outlined in Starter Removal and Installation preceding 2 Remove 2 thru bolts from starter a Thru bolts b Commutator End Cap 3 Tap commutator end cap to loosen and remove from starter frame Be careful not to lose brush springs 4 Brush replacement is recommended if brushes are pitted chipped or worn to less than 1 4 6 4mm If necessary remove brushes as fol lows a Lift brush holder from end cap Remove hex nut and washers from positive terminal and remove positive brushes along with positive terminal as an assembly 11656 a Brush Holder b Negative Brushes c Positive Brushes d Positive Terminal 90 814676R1 DECEMBER 1996
251. g Pull Adjustment The steering on some boats will have the tendency to pull towards starboard This pulling condition can be corrected by using a pliers and bending the ends of the exhaust fins 1 16 in 1 5mm toward the star board side of the outboard a Exhaust Fins Impeller Clearance Adjustment 1 The impeller should be adjusted so there is approximately 0 03 in 0 8mm clearance be tween the impeller edge and liner Operating the jet drive in waters that contain sand and gravel can cause wear to the impeller blades and the clearance will start to exceed 0 03 in 0 8mm As the blades wear shims located in the stack out side of the impeller can be transferred behind the impeller This will move the impeller further down into the tapered liner to reduce the clearance 2 Check the impeller clearance by sliding a feeler gauge through the intake grate and measure the clearance between the impeller edge and liner If adjustment is required refer to Impeller Removal and Installation a Shims 6B 10 LOWER UNIT Q Worn Dull Impeller Do not sharpen or alter the top side lifting angle Enlarged leading View edge Sharpen to 1 32 in 8mm radius by removing material from bottom side only The intake of gravel through the pump can round off and wear the leading edges on the impeller Some conditions you may experience from a worn impeller are 1 a noticeable performance loss especially on
252. g from the bearing carrier Heat the bearing carrier with a torch only until you can barely touch it Hold the drive shaft vertical and bump the impeller end of the drive shaft against a wooden block causing the bearing carrier to slide down off the bearing Remove snap ring press the ball bearing off the drive shaft Leave the bearing thrust ring located in the drive shaft groove unless damaged Remove the seals and spiral retaining rings from the bearing carrier and the upper seal housing Clean all parts thoroughly and remove any burrs Snap Ring Bearing Carrier Ball Bearing Upper Seal Housing Snap Ring Thrust Ring DECEMBER 1996 Bearing Carrier Reassembly Installing Lower Seals Install seals into bearing carrier as follows 1 Install O ring seals into the top seats of the three passage holes Install spiral retaining ring into the inner ring groove Spread a film of grease around the inside bore of the seal surface before pressing in the seals Press in the garter spring seal against the inner retaining ring as shown Fill the garter spring cav ity in the seal with grease Install spiral retaining ring into the outer ring groove Align the notched ends of the retaining ring to straddle the small vent hole drilled in the ring groove Press in the outer seal against the retaining ring as shown Grease all the seal lips IMPORTANT The no
253. ge 90 814676R1 DECEMBER 1996 Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up solenoid located under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the side of the trim ram The trim cylinder trim ram will position the engine at the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum trim angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine speed increases above 2000 RPM the thrust created by the propeller if deep enough in the water should cause the trim system to automatically lower the engine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering condi tions Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle tilt pin relocation Will help planing off particularly with
254. ge or corrosion Thoroughly clean damaged or cor roded areas and apply matching paint Quicksil ver Spray Paints 10 Check trim tab and galvanic corrosion inhibitor for damage or for deterioration from salt water operation 11 Check remote controls and steering Be sure that all connections and fittings are in good condition properly secured and correctly adjusted 90 814676R1 DECEMBER 1996 Flushing Outboard Cooling System When flushing be certain that area in vicinity of propeller is clear and that no person is standing nearby to avoid possible injury It is recom mended to remove propeller as a precautionary measure 1 Install Quicksilver Flushing Attachment 44357A2 or equivalent tool on the gear hous ing from the FRONT side positioning the rubber cups over the water intake openings Typical Gear Housing a Water Hose 1 2 in 13mm I D or Larger b Flushing Attachment 44357A2 2 Connect hose 1 2 in 13mm I D or larger be tween flushing attachment and water tap IMPORTANT To prevent water pump damage do not start or run engine unless cooling water is flowing 3 With the outboard in normal operating position vertical partially open water tap IT IS NOT NECESSARY to use full water pressure and ad just water flow so that there is a significant water loss around the rubber cups 4 Start engine and idle in neutral Then increase engine speed not to exceed 2500 RPM IMPORTANT
255. ge to shock piston 90 814676R1 DECEMBER 1996 A 4 Place shock rod into soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 5 Loosen shock rod piston using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs 6 Allow shock rod piston to cool Remove from shock rod 51146 51146 a Shock Rod Piston b Spanner Wrench 90 814676R1 DECEMBER 1996 CAUTION Do not remove check ball components from shock rod piston Removal and reinstallation of check valve could result in improper operating pressure and possible manual tilt system dam age 7 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly 8 Clean shock and components with compressed air 9 Remove inner O ring 51199 O ring b Shock Piston 10 Remove cylinder end cap assembly from shock rod 11 Inspect shock If wiper located in cap has failed to keep rod clean replace wiper MID SECTION 5F 25 12 Place end clean work surface 13 Remove rod wiper inner O ring and outer O ring 51147 51145 a Rod Wiper b Inner O ring Outer O ring 5F 26 MID SECTION c 1 Remove valve block from shock rod cylinder Valve Block Removal 51146 a Screws 2 b Valve Block c Shock Rod Cylinder 2 Remove O rings 90 814676R1
256. ght clockwise position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Bleeding Power Trim Unit 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls down to trim position indicates debris or defective com ponents in trim valve assembly Clean or replace components as required 5 Check manual release valve for broken stem and one O ring remaining in the release valve pas sage Separate the manifold assembly from the cylinder to dislodge broken stem Install new re lease valve and test system 6 Check for nicked deteriorated or misplaced O rings throughout trim system 5C 12 MID SECTION c Leak Down Check Pump and Man ifold Assembly NOTE Scribe d pump housing halves before disas sembly Check pump for problems as follows 1 Debris or chips between valve and seat a Usu ally imbedded in rubber valve seat Nicked or deteriorated O ring b Nicked deteriorated or misplaced O ring be tween manifold and trim cylinder Refer to ifold Removal for O ring location 4 After reassembly insert drive shaft and check pump rotation resistance to turning housing halves can shift turn during reassembly Align scribe marks d carefully 90 814676R1 DECEMBER 1996 Leak Down Check Pilot Valve As sembly 1 Debris or chips be
257. gnition point file Recheck switch if full continuity is not indicated re place end frame MID SECTION 5C 29 Armature Tests TEST FOR SHORTS Check armature on a Growler follow Growler man ufacturer s test instructions Indication of a short re quires replacement of armature TEST FOR GROUND Use an Ohmmeter R x 1 scale Place one lead on Ohmmeter on armature shaft and other lead on com mutator as shown If continuity is indicated armature is grounded and must be replaced 51195 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down on an armature conditioner tool or on a lathe Clean commutator with 00 sandpaper adi MESS 358 aam 5C 30 MID SECTION Power System Reassembly Manifold Oil Pump Installation IMPORTANT Install spring check valve and O ring into manifold Position components in place using sleeve to seat in place 50999 1 Install check valve components into manifold lt 0 d lt 0 8 9 GEFN Ae 25 9 51008 Manifold Spring Check Valve Check Valve Seat O ring Spring Sleeve Spool 90 814676R1 DECEMBER 1996 p 2 Install O rings on cylinder and secure manifold 4 Install check valve components and O rings to assembly to cylinder using screws Torque manifold Secure oil pump to manifold using bolt screws to 100 Ib in 11 3
258. gs Replace O rings Replace oil pump 5B 14 MID SECTION 90 814676R1 DECEMBER 1996 Troubleshooting Flow Diagram Outboard will not hold tilted position in reverse and or trails out during high speed decelera tion Inspect Manual Release Valve Result Result Manual release valve and O rings Manual release valve and or O ring damage appear to be OK Replace O rings and proceed Replace defective valve and O Inspect Trim Rod Piston Check rings Valve Result Result No debris or defective components Debris found in check valve com found ponents Inspect Manifold Reverse Thrust Clean check valve components Valve using engine cleaner and com pressed air or replace CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FACTORY FOR PRECISE REVERSE THRUST PRESSURE AND DOES NOT RE QUIRE ADJUSTMENT REVERSE THRUST VALVE COMPONENTS CAN ONLY BE CLEANED USING ENGINE CLEANER AND COM PRESSED AIR THROUGH MAN IFOLD PORTS WHILE VALVE COMPONENTS REMAIN IN MAN IFOLD Result Result Debris found in manifold reverse No debris found in manifold re thrust valve components verse thrust valve Clean manifold reverse thrust Replace Manifold as a Unit valve without removing compo nents using engine cleaner and compressed air or replace 90 814676R1 DECEMBER 1996 MID SECTION 5B 15 Electrical System Troubleshooting COMMANDER 2000 Side Mount Remo
259. h Retainer Tool Brush Retainer Tool Installed on Commutator End Cap 9 Install commutator end cap onto starter frame align mark on frame with positive terminal and re move brush retainer tool Install thru bolts and torque to 70 Ib in 7 9 N m 54657 a Alignment Marks b Align Mark with Positive Terminal 2B 16 ELECTRICAL AND IGNITION a 12 Volt Supply b Ohmmeter Leads cM 1 Disconnect all leads from solenoid terminals Starter Solenoid Test Test starter solenoid as follows 2 Using an ohmmeter R x 1 scale connect leads between solenoid terminals 1 and 2 as shown 3 Connect a 12 volt supply between solenoid ter minals 3 and 4 as shown Solenoid should click and meter should read zero ohms 4 If meter does not read zero ohms full continuity replace solenoid ul Lied iden 4 Ix um 14354 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION TIMING SYNCHRONIZING ADJUSTING Table of Contents Page Timing Synchronizing Adjusting 2C 1 Specifications 2 1 Special 016 2 1 Timing Adjustments 2C 1 Static Timing Outboard Not RUNNING osc eee nek eee eee Se dee ee 2C 1 Electric Start Models 2C 1 Throttle Primary Pick Up Adjustment 2C 1 Maximum Timing Adjustment 2C 3
260. h condition 5 Slowly turn idle mixture screw clockwise until the cylinders fire evenly and engine picks up speed 6 Continue turning screw clockwise until too lean a mixture is obtained engine slows down and mis fires 7 Setidle mixture screw at a point midway between TOO RICH and TOO LEAN When in doubt set slightly RICH rather than TOO LEAN 8 Donotadjustleaner than necessary to attain rea sonable smooth idling Too lean a setting is a ma jor cause of hard starting Float Adjustment 1 Remove carburetor as outlined in Carburetor Removal following 2 Remove float bowl and check float level and float drop 3 14 FUEL SYSTEM AND CARBURETION FLOAT LEVEL AND FLOAT DROP ADJUSTMENT Metal tab controls float level Plastic tab limits float drop Bending tab a towards needle when float is installed decreases float level NOTE Float must be replaced if float drop is out of adjustment a Metal Tab b Plastic Tab FLOAT LEVEL WMA7B CARBURETOR 1 On WMA7B carburetors adjust float level to 1 4 in 6 4mm from float bottom to casting as shown 90 814676R1 DECEMBER 1996 FLOAT DROP Main High Speed Jet Adjustment WMA7B CARBURETOR ONLY The carburetor is equipped with a fixed high speed jet 1 Float drop measurement of 1 32 in 0 793mm to and normally no adjustment is required However 1 16 in 1 587mm from bottom of float and top extreme changes in weather temperatur
261. h wiring harness in the bottom cowl and disconnect the black yellow wire that goes to the switch box 2 Route the remote control wiring harness e into the bottom cowl thru the wiring grommet Con nect the Y harness f P N 84 11149A1 sup plied with remote control between the remote control wiring harness and the disconnected black yellow wire connections as shown eo Engine Ground BLK YEL BLK YEL BLK YEL BLK YEL 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 23 OUTBOARD MOTOR INSTALLATION ATTACHMENTS TILLER HANDLE AND CO PILOT Table of Contents Page Tiller Handle Components 7B 1 Torque Specifications 7B 1 Quicksilver Lubricants and Service Aids 7B 1 Tiller Handle Throttle Cable Replacement 7B 2 Tiller Handle Installation 7B 5 Shift Link Rod Installation 7B 6 Throttle Cable Installation 7B 6 Lanyard Stop Switch Wiring 7B 8 Neutral Start Switch Wiring 7B 9 Battery Connections 7B 10 Co Pilot Installation Instructions 7B 11 Shift Interlock Adjustment 7B 12 7B 0 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 90 814676R1 DECEMBER 1996 p i Tiller Handle Components Quicksilver Lubricants and Service 1 Steering Arm Aids 2 Washer 3 Nut 2 4 C Marine Lubricant 4 Grip
262. han specified replace stator ELECTRICAL AND IGNITION 2A 11 Test For Spark Cranking Cun qr bp SS TBS BS E a 5 2 5 Spark Tester 91 850439 Connect Ground Lead To Engine Ground o 1 Remove the spark plug leads from the spark plugs 2 Adjustthe spark tester to 1 2 in 12mm gap set ting 3 Connectthe spark plug leads to the tester Attach the tester ground lead to engine ground 4 Crankthe engine Spark should jump each tester gap TEST RESULTS NOTE Normal ignition spark is BLUE in color A YELLOW or RED spark indicates a weak ignition Normal spark on all cylinders Go to Primary Volt age Test Engine Running e Intermittent weak or no spark output on all cylin ders usually indicates a defective trigger Go to Trigger Test e Intermittent weak or no spark output on any one cylinder indicates a bad ground defective igni tion coil defective spark plug lead or switch box Go to Ignition Coil Test 2 12 ELECTRICAL AND IGNITION Primary Voltage Test Engine Running a b 9 1 BLACK Plug into Meter Attach to Appropriate Terminals Attach to Engine Ground Selector Switch If the ignition system tests OK it may be neces sary to check the output voltage while running the engine under load
263. he check valves e h i amp j to close The closed check valves prevent the oil from traveling between cavities and locks the engine into position 90 814676R1 DECEMBER 1996 MID SECTION 5G 5 Shock Rod b End Cap Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 6 MID SECTION Down Circuit Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston Shock Return Valve p Impact Relief Valve 90 814676R1 DECEMBER 1996 Tilt Down With the engine tilted up the piston inside the accu mulator piston d will be at the bottom of the accumu lator c and the gas pressure is low To lower the en gine the camshaft lever f is rotated down the internal cam will cause the push rods to open the ac cumulator check valve e both fast transfer valves h amp j and the down slow transfer valve i The oper ator will have to press down on the engine cowl to overcome the pressure inside cylinder Fluid will flow out of the bottom of the cylinder past both the down fast transfer valve h and down slow transfer valve i Fluid will flow past the up fast transfer valve j surge valve k and through the interconnecting pas sage into the top of the cylinder 1 Due to the shock rod a the tilt cylinder cavities differ in volume the extra f
264. he decal Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface Wipe decal surface with soft paper towel or cloth Wait 10 15 minutes Starting at one corner carefully and slowly pull the masking off the decal surface at a 180 angle NOTE To remove any remaining bubbles pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb moving toward the puncture 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION IGNITION SYSTEM Table of Contents Page Ignition System 2 1 Description 2 1 Ignition Troubleshooting 2A 2 Checking For Loss Spark 2A 2 Troubleshooting Test Equipment 2 2 Ignition Troubleshooting Engines With Black 5 2A 3 Ignition Troubleshooting Engines With Red 5 2A 7 Ignition Component Testing 24 10 Trigger Test 223552555555 24502 ER ed 2A 10 Ignition Coil 24 10 Test For Spark 2A 12 Running Voltage Output Test 2A 12 Ignition Key Switch Test 2
265. hooting Fuel Pump Problem Air Bubbles in Fuel Line Possible Cause Corrective Action Low Fuel in Tank Fill Tank with Fuel Loose Fuel Line Check and Tighten All tion Connections A Hole or Cut in Fuel Line Check Condition of all Fuel Lines and Replace any Found to be Bad Fuel Pump Anchor Tighten all Screws Evenly Screw s Loose and Securely Fuel Pump Gasket s Rebuild Fuel Pump Worn Out 90 814676R1 DECEMBER 1996 Fuel Pump Removal Electric Start Model An Anti siphon Valve Read Checking for re stricted Fuel Flow Caused 1 Remove oil tank from outboard Refer to Section by Anti siphon Valves 8 Oil Injection System Preceding Air in Fuel Line Air Bubbles in Fuel Line Preceding A Dirty or Clogged Fuel Replace Fuel Filter Filter The Fuel Pickup in Fuel Clean or Replace Pickup Tank Clogged or Dirty Worn Out Fuel Pump Dia Rebuild Fuel Pump phragm Defective Hole or Crack Rebuild Fuel Pump Check Valve s in Fuel Pump Broken Check Valve Re Rebuild Fuel Pump tainer Pulse Hole Plugged Remove Fuel Pump and Clean Out Hole Loose Pulse Hose Tighten Connection Boost Diaphragm Gasket Check Seal Between Distorted or Out of Place ing Surfaces Where Rib Divides Pulse Chamber Gasket Must Align with Rib Check for Distorted a Inlet Hose Gasket Align or Replace b Outlet Hose Gasket if Necessary 3 Remove 2 screws securing fuel pump to power head 2 Remo
266. hread lifting ring 91 90455 into flywheel hub a minimum of 5 turns Replace plastic cap after installation 2 Manual Start Models Use lifting harness b 91 64400A2 90 814676R1 DECEMBER 1996 Installing Outboard On Boat Transom Models Without Transom Clamp Handles a Mounting Bolts 4 b Flat Washers 4 c Locknuts 4 DO NOT under any circumstances allow upper outboard mounting bolts to be closer than 1 inch 25 4mm from top of boat transom Upper mounting bolts must never be installed thru shims NOTE When drilling into a fiberglass boat place masking tape directly onto boat where mounting holes will be drilled to help prevent fiberglass from chipping It is recommended for best all around boating perfor mance the outboard should be mounted so the anti ventilation plate a is in line with the boat bottom Use a 17 32 inch 13 5mm diameter drill bit and drill two mounting holes for the upper set of mounting bolts and two holes for the lower set of mounting bolts OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 1 NOTE If using Transom Drilling Fixture P N 91 98234A2 use holes f when drilling outboard mounting holes e Centerline of Transom f Use These Drilling Holes NOTE On some boats because of transom interfer ence it may be necessary to install the steering cable before fastening the outboard to the transom Position outboard on boat transom Al
267. ht inside the boat persons and gear has a significant effect on the boat s performance for example a Shifting weight to the rear stern 1 Generally increases top speed 2 in excess can cause the boat to por poise 3 Can make the bow bounce excessively in choppy water 4 Will increase the danger of the following wave splashing into the boat when com ing off plane b Shifting weight to the front bow 1 Improves ease of planing off 2 Generally improves rough water ride 3 If excessive can make the boat veer back and forth bow steer 2 Boat Bottom For maximum speed a boat bot tom should be nearly a flat plane where it con tacts the water and particularly straight and smooth in fore and aft direction a Hook Exists when bottom is concave in fore and aft direction when viewed from the side When boat is planing hook causes more lift on bottom near transom and allows bow to drop thus greatly increasing wetted surface and reducing boat speed Hook frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage b Rocker The reverse of hook and much less common Rocker exists if bottom is convex in fore and aft direction when viewed from the side and boat has strong tendency to por poise c Surface Roughness Moss barnacles etc on boat or corrosion of outboard s gear hous ing increase skin friction and cause speed
268. ht switch box mounting bolt Torque bolt to 40 Ib in 4 5 N m 2 Attach warning module to electrical box with 2 bolts Torque bolts to 40 Ib in 4 5 N m 54867 a Warning Module b Bolts Torque to 40 Ib in 4 5 N m 3 Reinstall electrical box access cover 4 Reinstall top cowling 5 Reconnect engine battery cables to battery 8 10 OIL INJECTION SYSTEM A Engine Mounted Oil Reservoir Removal 1 Disconnect engine battery cables from battery 2 Verify ignition key is in the OFF position 3 Remove top cowl 4 Remove 3 bolts securing flywheel cover to pow erhead and remove cover 54640 a Bolts b Flywheel Cover 90 814676R1 DECEMBER 1996 Q 5 Tiltoil reservoir to gain access to bottom of oil res Installation ervoir f 1 Connect oil outlet hose to elbow fitting on oil res 6 Remove screw securing oil level sensor in bot ervoir Secure hose with STA STRAP tom of oil reservoir and remove sensor 2 Insert oil level sensor into bottom of oil reservoir A CAUTION Secure sensor with screw Oil level sensor is FRAGILE Handle with care 3 Position oil reservoir upright with bottom of reser voir seated in support pocket in engine tray
269. hus not us ing trim adjustment pin may be desired However some boats with engine trimmed to the full trim angle at planing speeds will cause undesir able and or unsafe steering conditions If these steering conditions are experienced under no circumstances should the engine be operated without the trim adjustment pin and without the pin adjusted in the proper holes to prevent un safe handling characteristics Water test the boat not using the trim adjustment pin If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment pin in proper hole to prevent unsafe han dling characteristics 90 814676R1 DECEMBER 1996 c System NOTE It is recommended that ALL O rings be re placed when servicing tilt system Components 1 Trim Rod 1 2 Dowel Pin Upper Torque Specifications 3 Upper Pivot Pin 4 Rod Wiper 35 Ib in 4 0 5 O ring 671 in 1 0 Oylinder Cap 9 100 lb in 11 2 O ring 1 864 in I D O ring 614 in 1 0 70 lb in 7 9 N m Trim Rod Piston 10 Ball 5 90 lb in 10 2 2 8 N m 1 5 N m 11 Spring Seat 5 12 Spring 5 Q 25 lb in 13 Retaining Plate 14 Screw 5 13 Ib 15 O ring 1 600 in 1 0 Rod Piston 16 O ring 1 600 in 1 0 Memory Piston P MERO Quicksilver Lubricants and Service 18 Trim Rod Cylinder 19 Screw 2
270. ifold h Down Fast Transfer Valve 5G 4 MID SECTION Up Circuit Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston Shock Return Valve p Impact Relief Valve 90 814676R1 DECEMBER 1996 Tilt Up With the engine in the down position the accumula tor piston d will be at the top of the accumulator c with the gas at maximum pressure To raise the en gine the camshaft lever f is rotated all the way down The internal shaft connected to the camshaft lever will move the push rods opening the accumula tor check valve both fast transfer valves h 8 and the down slow transfer valve i As the operator lifts the engine oil under pressure inside the accu mulator will flow around both the slow transfer valve i and the down circuit fast transfer valve h Oil flows into the bottom of the tilt cylinder forcing the memory piston m into the shock piston n and then forcing the shock rod a up and out Oil above the shock piston exits the cylinder 1 through an intercon necting passage along side of the cylinder and re turns into the manifold g Inside the manifold the oil flows past the groove in the surge valve k through the transfer valve j and mixes with the oil flowing from the accumulator into the up cavity With the en gine in the correct position the camshaft lever f is rotated up and the push rods allow t
271. ign the mount ing holes in the transom brackets that will place the outboard nearest to the recommended mounting height Apply marine sealer to shanks of mounting bolts not threads and secure outboard to transom with 4 bolts flat washers and locknuts as shown Be sure that in stallation is water tight g 1 2 Inch Diameter Bolts 4 h Flat Washers 4 Locknuts 4 A CAUTION Marine sealer must be used on shanks of mount ing bolts to make a water tight installation 7A 2 OUTBOARD MOTOR INSTALLATION ATTACHMENTS Q Installing Outboard On Boat Transom Models With Transom Clamp Handles a Transom Clamp Handles DO NOT under any circumstances allow the cupped washers on the ends of the transom clamp screws to be closer than 1 inch 25 4mm from top of real boat transom not shims NOTE When drilling into a fiberglass boat place masking tape directly onto boat where mounting holes will be drilled to help prevent fiberglass from chipping Itis recommended for best all around boating perfor mance the outboard should be mounted so the anti ventilation plate b is in line with the boat bottom Before operation the outboard must be correctly installed with four mounting bolts shown Failure to correctly fasten outboard could result in out board ejecting off boat transom causing serious injury death or property damage 90 814676R1 DECEMBER 1996 c IMPORTANT Outboards with transom c
272. ils out of the housing Installing Used Rewind Spring 1 Lubricate rewind spring with low temperature grease To enable sheave to rotate when installing rewind spring place bushing and sheave shaft into sheave Add flat washers below sheave to raise sheave above vise Secure sheave shaft in vise that is equipped with soft jaw protectors Engage hook on end of spring into sheave 4 Turn sheave clockwise while feeding spring into recess and use thumbs to guide rewind spring into recess Proceed cautiously do not allow spring to get out of control Remove sheave from vise and remove sheave shaft and bushing Sheave Shaft Bushing Sheave Flat Washers Allowing Enough Clearance for Sheave to Rotate Above Vise Hook Spring in Notch Turn Sheave Clockwise while Feeding Spring into recess Vise with Soft Jaw Protectors 7C 4 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 54851 a Push Rewind Spring into Recess while Turning Sheave Clockwise Installing New Rewind Spring 1 Remove retainers used to keep spring from acci dentally coming out of shipping container Place hook on end of spring into sheave anchor and place support tabs a on container above spring recess as shown Insert 2 large bit screwdrivers thru openings b and push spring out of shipping container and into spring recess in sheave 90 814676R1 D
273. ilt ram The tilt ram will move the engine downward to the desired angle MID SECTION 5B 1 Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running While operating up circuit tilt ram will continue to tilt outboard to full up position for trailering Tilting Outboard Up and Down Manually Before loosening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is loos ened With power trim installed the outboard can be raised or lowered manually by opening the manual release valve 3 to 4 turns counterclockwise 50146 a Manual Release Valve 5B 2 MID SECTION Trim Angle Adjustment Operating some boats with engine trimmed to the full in trim angle not using trim adjustment pin a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after engine installation and after any trim adjust ments IMPORTANT Some boat motor combinations that doe not use the trim adjustment pin a and are trimmed to the full trim angle will not ex perience any undesirable and or unsafe steering conditions during planing speed T
274. ilter 50 Valve Seat 51 O ring 364 1 0 52 Ball 53 Spring Guide 54 Spring 55 Hole in Cyliner Quicksilver Lubricant Sealant Application Points DESIGN 1 DESIGN 2 M t 600 e AA NV X Lubricate ALL O rings using Quicksilver Power Trim and Steering Fluid or ATF Type FA or Dexron Il Loctite Grade A 271 Loctite Pipe Sealant with Teflon 592 Special Lubricant 101 NOTE NOTE It is recommended that ALL O rings be replaced when servicing tilt system 90 814676R1 DECEMBER 1996 MID SECTION 5F 1 Manual Tilt System Components Design Three Torque Specification Valve Block 35 lb ft 47 Nm L Pivot Pin 100 lb in 11 2 N m 351b in 4 0 N m 27 Ib in 3 0 75 lb in 8 5 Rod Wiper O ring 671 in 1 0 Oylinder Cap 10 O ring 1 864 in 1 0 11 O ring 614 I D 12 Shock Rod Piston 13 Ball 5 14 Spring Seat 5 15 Spring 5 16 Retaining Plate 17 Screw 3 18 O ring 1 600 I D Shock Piston 19 O ring 1 600 I D Memory Piston 20 Memory Piston 21 Screw 2 22 O ring 208 in 1 0 2 23 Plug 24 Spring Large 25 Spring Small 26 Ball DESIGN 3 27 Plunger 28 Screw Plug 2 29 Spring 2 30 O ring 2 31 Ball 2 32 Push Rod 2 33 Dowel Pin 34 Spool 35 Spring 36 O ring 301 in I D 37 Screw Plug 38 O ring
275. im angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine RPM increases above 2000 RPM the thrust created by the propeller if deep enough in the water will cause the trim system to automatically lower the engine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering condi tions Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle tilt bolt relocation Will help planing off particularly with a heavy load Usually improves ride in choppy water In excess can cause boat to veer to the left or right bow steer Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt bolt one hole closer to transom MID SECTION 5D 1 Operating Down circuit will actuate the down relay located under engine cowl and close the electric motor circuit motor will run in opposite direction of the Up circuit The electric motor will drive the pump forcing fluid thru internal passageways into the down side of the tilt ram The tilt ram will move the engine down to the desired angle Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear ho
276. im switch is activated in the up position the electric motor c begins to rotate the pump gears j the oil pump draws a small amount of oil through the filter g and through the up circuit suction port i The oil pump gear j rotation forces oil into the pas sages for the up circuit Oil under pressure will slide the shuttle valve m against the down circuit pres sure operated valve f The shuttle valve will me chanically open the down pressure operated valve allowing oil from the down cavity of the trim cylinder to flow into the oil pump This returning oil from the down cavity will supply most of the oil required for the up circuit Oil in the up circuit is blocked from return ing into the reservoir by the ball inside the down cir cuit suction port k The pressure of the oil will force the up circuit pressure operated valve n to open al lowing the oil to enter the passages inside the man ifold q leading to the trim cylinder w up cavity Cil is blocked from all other passages by the closed manual tilt valve p Oil under pressure will enter the trim cylinder below the memory piston t With an in creasing amount of oil entering the cylinder the memory piston contacts the shock piston u and forces the piston rod a up and out raising the out board motor Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and enters the manifold passages The oil is drawn
277. im tab in neutral straight fore and aft posi tion you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at high speed reduce the power gradually and trim the motor in slightly before resuming high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instabili ty Will lift bow of boat generally increasing top speed Transfers steering torque harder to left on installa tions below 23 transom height Increases clearance over submerged objects In excess Can cause porpoising and or ventilation In excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow erhead overheating damage Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage 90 814676R1 DECEMBER 1996 Make sure that water level is above gear housing water intake holes whenever engine is running Operating up circuit will actuate the up solenoid located under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid thru internal passageways into the up side of the trim cylinder The trim cylinder trim ram will position the engine at
278. im tab to the left If boat pulls to the right ad just trailing edge of trim tab to the right d Tighten trim tab bolt securely and replace plug e Operate boat per Check trim tab position as follows preceding to check trim tab setting If necessary readjust trim tab a Anti Ventilation Plate b Adjustable Trim Tab c Plug 1 6 IMPORTANT INFORMATION PAS Boat Performance Test Instructions A tight grip on the steering wheel tiller handle is always advisable and is required when accelerat ing decelerating or when trimming the boat On models with Power Trim upon reaching cruising speed the outboard should be trimmed to obtain a balanced steering condition While trimming steering loads will vary and will pull in one direc tion until a balanced condition has been attained If the outboard is trimmed past the balanced steering condition the steering wheel tiller han dle then will have a tendency to pull in the oppo site direction Excessive trimming past the bal anced steering position will result in increased steering loads and in most boat applications a decrease in performance A CAUTION When trimming boat with dual outboards both outboards should be at approximately the same tilt angle and be tilted out up simultaneously to prevent boat from pitching side to side until de sired boat attitude is achieved Outboards can then be trimmed individually to precisely adjust boat trim angle and pitch
279. in This will shear cross a Pivot Pin 50515 a Upper Pivot Pin 5D 14 MID SECTION 90 814676R1 DECEMBER 1996 8 Tilt power trim assembly top first out from clamp Power Trim System bracket and remove assembly Disassembly Trim Rod Removal 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three turns maxi mum counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs 9 Remove fill screw and drain unit a Manual Release Valve b Manifold c Spanner Wrench P N 91 74951 4 Remove trim rod assembly from cylinder a Fill Screw 10 Remove O ring from fill cap 51196 90 814676R1 DECEMBER 1996 MID SECTION 50 15 5 Remove memory piston from cylinder using lock ring pliers Craftsman P N 4735 or suitable tool 51193 51196 a O ring b Memory Piston 7 Remove trim system from vise and empty fluid into appropriate container 5D 16 MID SECTION c Trim Rod Disassembly 1 Place trim rod assembly on clean work surface 2 Remove screws securing plate to trim rod piston and O ring 3 Remove check ball components from trim rod piston a Screw 3 b Plate c O ring d Piston A CAUTION When removing Trim Rod piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to trim piston 90 814
280. iner c 7B 6 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 5 Check shift link rod adjustment as follows a Place outboard shift lever in F Forward position Propeller should not rotate in a COUNTERCLOCKWISE direction If propel ler does rotate COUNTERCLOCKWISE length of shift link rod must be reduced and Step a repeated b Place outboard shift lever in N Neutral position Propeller should rotate freely with out drag If not length of shift link rod must be increased and Steps a and b repeated c While rotating propeller place outboard shift lever in reverse position If propeller can be rotated in either direction length of shift link rod must be increased and Steps a thru repeated d Place outboard shift lever in N Neutral position Propeller should turn freely without drag If not length of shift link rod must be de creased and Steps a thru d repeated Throttle Cable Installation 1 Rotate throttle twist grip fully clockwise to stop IDLE position 20888 2 Back out set screw a from throttle cable barrel 0 until 2 or 3 threads of set screw are exposed 54831 90 814676R1 DECEMBER 1996 3 Placebarrel receptacle c onto throttle barrel d 5 Place end of throttle cable c on peg of throttle Route throttle cable e around port side of out lever d board and position throttle cable
281. ing Drive Shaft 1 Lubricate the seals and inside bore of the bearing carrier Place the drive shaft b impeller end facing up into a vise Heat the bearing carrier until it feels warm to the touch Place the bearing carrier onto the drive shaft Square up the inner bore with the ball bearing and push the bearing carrier down until it bottoms out against the bearing It may be necessary to lightly tap bearing carrier onto the bearing using a rub ber hammer NOTE Only a light pressing force is needed to press on the bearing carrier It may be necessary to lightly tap the bearing carrier onto the bearing using a rubber hammer a Bearing Carrier b Drive Shaft 90 814676R1 DECEMBER 1996 5 Grease upper seals and inside bore of the 7 nstall spacer and the upper seal housing being bearing carrier to ease entry of the seal housing careful not to damage the O ring seals as they pass the snap ring groove Only finger pressure 6 Install the thrust washer against the ball bearing should be necessary to push in the housing 8 Install the beveled snap ring beveled side facing up into the ring groove Make sure the snap ring is fully seated into groove a Snap Ring b Upper Seal Housing Spacer d Thrust Washer 90 814676R1 DECEMBER 1996 LOWER UNIT 6B 15 Jet Drive Handle Adaptor Kit Installation Instructions NOTE This kit must be used in co
282. ing eye and turn eye in or out to correct align ment Both steering eyes MUST BE threaded into cou pler 3 4 in 19mm minimum and jam nut must be tightened against coupler to prevent coupler from turning Torque jam nut to 20 Ib ft 27 Tighten jam nut against coupler Torque jam nut to 20 Ib ft 27 N m Spray Quicksilver Corrosion Guard on exposed threads of steering eyes and position rubber bush ings and rubber sleeves to cover exposed threads of steering eyes After installation is complete and before operat ing outboards check that boat will turn right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interference free movement Adjust trim tabs of both outboards as outlined in Trim Tab Adjustment following 90 814676R1 DECEMBER 1996 c Steering Coupler Installation IMPORTANT Dual outboard installation requires a minimum outboard centerline distance of 21 in 533mm to assure interference free movement IMPORTANT Lubricate all moving parts with Quicksilver 2 4 C Multi Purpose Lubricant a Steering Link Connecting Hole b Coupler Assembly Connection Hole 40 Model Steering Link Supplied on Outboard d Washer Supplied with Steering Link e Ride Guide Cable f Steering Bracket Supplied in Kit g Special Washer Head Bolt Supplied in
283. ing procedure before attempting any change in shim thickness 1 Cleanreverse gear shoulder and diameter of pro peller shaft cavity 2 Insert shimming tool 91 89670 into gear hous ing until it bottoms out 3 Align access hole in shimming tool with pinion gear 4 Rotate drive shaft several times with down pres sure applied to seat drive shaft tapered bearing 5 With down pressure applied determine pinion gear depth by inserting a feeler gauge through access hole in shimming tool 6 The correct clearance between pinion gear and shimming tool is 025 in 0 64mm 7 If clearance is incorrect add or subtract shim s under drive shaft tapered bearing race to raise or lower pinion gear 8 Add Loctite Grade A to threads of pinion nut when reinstalling 6A 20 LOWER UNIT e BATTLE 50507 a Apply Pressure in Direction of Arrow b Shimming Tool Feeler Gauge d Obtain 025 in 0 64mm Clearance Between Shimming Tool and Pinion Gear Propeller Shaft Reassembly and Installation 1 Insert spring into propeller shaft a Spring 2 Install sliding clutch Sliding Clutch Hole Must Align with Slot c Slot Short Side 90 814676R1 DECEMBER 1996 3 Insert guide block a into propeller shaft Cross 6 Install spring a pin hole
284. ings and rod wiper to end ing spanner wrench 1 4 in x 5 16 in long peg cap e 51145 a Rod Wiper b Inner O ring Outer O ring 2 Secure trim rod in soft jawed vise as shown 3 Slide end cap onto trim rod a Trim Rod Piston b Spanner Wrench Install lubricated O ring to trim rod piston Install check ball components into its respective bore 7 Secure components in place using plate and screws Torque screws to 35 in 4 0 N m 51146 a End Cap 51147 Screw 3 Plate O ring Ball 5 Seat Spring 5 Spring 5 50 24 MID SECTION 90 814676R1 DECEMBER 1996 Q Trim Rod Installation 4 Install trim rod into cylinder 1 Place trim cylinder in soft jawed vise 2 Fill trim cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steering Fluid or ATF Type FA or Dexron Il 3 Install lubricated O ring to memory piston and place into cylinder Push piston down to level of oil Memory piston must not contact end cap during trim rod end cap installation 51196 5 Tighten end cap assembly to cylinder securely using spanner wrench 1 4 in x 5 16 in long pegs 51144 a O ring b Memory Piston 51145 a Spanner Wrench P N 91 74951 6 Tighten manual release valve snuggly following end cap installation 90 814676R1 DECEMBER 1996 MID SECTION 5D 25 cM Purging Power Trim Unit Power T
285. ion following IMPORTANT It is recommended that heat be ap plied carefully to end cap housing to aid in re moval of ball bearing 54695 a Lower End Cap b Ball Bearing Puller 91 24100A1 3 Drive oil seals from end cap with a suitable punch Discard oil seals Design 1 End Cap a Oil Seals Design 2 End Cap a Oil Seals Design 3 End Cap a Oil Seals 4 22 POWERHEAD Crankshaft Disassembly Eye Protection must be worn while removing pis ton rings and piston pin lock rings from pistons 1 Remove piston rings from pistons with Piston Ring Expander 91 24697 Discard piston rings 54696 a Piston Ring Expander 91 24697 90 814676R1 DECEMBER 1996 O 2 Remove piston pin lock rings from both ends of piston pin bores Discard lock rings DO NOT re use piston pin lock rings 54697 a Piston Pin Lock Ring One Each Side b Needle Nose Pliers 3 Use an awl and mark each connecting rod and piston with the same number as the cylinder to which it is installed Mark connecting rods on the I beam and piston on inside of skirt 54698 a Scribe Identification No on Connecting Rod and Inside of Piston Skirt 90 814676R1 DECEMBER 1996 4 Place Piston Pin Tool 91 76160A2 into top of piston pin Support bottom of piston with hand and tap on
286. is an open circuit in wire be tween Point 5 and Red terminal on the back of the ignition switch 90 814676R1 DECEMBER 1996 Q Power Trim System Removal Support outboard with tilt lock lever when servicing power trim system 1 Disconnect power trim harness from outboard wiring harness 2 Remove screw and clip securing wiring harness to clamp bracket 3 Use suitable tool to remove DRIVE DOWN up per dowel pin Retain dowel pin a Dowel Pin 4 Use suitable punch to drive out upper pivot pin Co LJ 4 A t ELA gt 41 f 51144 Pivot Pin 90 814676R1 DECEMBER 1996 5 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin a Dowel Pin 6 Use suitable punch to drive out lower pivot pin x QT 51144 a Pivot Pin MID SECTION 5B 21 7 Tilt power trim assembly top first out from clamp bracket and remove assembly 5B 22 MID SECTION 9 Remove O ring from fill cap Power Trim System Disassembly Trim Rod Removal 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three or four turns counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using spanner wrench 1 4 in x 5 16 in long pegs 51194 a Manual Release Valve 90 814676R1 DECEMBER 1996 p i 4 Remove trim rod assembly from cylinder 6 Remove O
287. is approxi mately the same as a standard size piston therefore it is not necessary to re bore all cylinders in a block just because one cylinder requires re boring 2 After honing and thoroughly cleaning cylinder bores apply light oil to cylinder walls to prevent rusting Pistons NOTE To assure lasting repairs and proper engine operation after repairs it is important that piston rings be replaced IMPORTANT If engine was submerged while en gine was running piston pin and or connecting rod may be bent If piston pin is bent piston must be replaced Piston pins are not sold separately because of matched fit into piston If piston pin is bent connecting rod must be checked for straightness refer to Connecting Rods fol lowing on how to check straightness 1 Check pistons for scoring cracks metal damage and cracked or worn piston pin bosses If any of these conditions are found replace piston s 4 26 POWERHEAD 2 Inspect piston ring grooves for wear burns dis tortion or loose piston ring locating pins 3 Clean piston dome ring grooves and piston skirt Use recessed end of a broken piston ring to clean carbon deposits from ring grooves DO NOT use an automotive type ring groove cleaner as this type tool could loosen piston ring locating pins 54705 4 Clean carbon deposits from top of pistons with a soft wire brush carbon removal solution or sand blasting When wire brushing top of piston DO
288. is or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a O ring 90 814676R1 DECEMBER 1996 Leakage Past Ball and Seat Piston Assembly Unit will trim to full or near full DOWN position and then will begin to trim UP while trim switch is held in DOWN mode If trim switch is released outboard can be pushed by hand DOWN to the point where trim UP started 1 Inspect balls and seats in piston assembly for de bris or damage or replace balls seats a Ball and Seat Check for Debris or Damage MID SECTION 5B 13 Troubleshooting Flow Diagram Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceler ation Inspect Manual Release Valve Result Result Manual release valve and O rings appear to be OK Replace O Manual release valve and or O ring damage rings rings Inspect Memory Piston O ring Replace defective valve and O Result Result O rings appear to be OK Cylinder O ring memory piston or cylinder bore and memory piston are OK bore defective Replace O rings and proceed Inspect Pump O rings located Replace defective O rings or below oil pump components Result Result O ring failure located below oil O rings appear to be OK Re pump place O rin
289. is quickly pushed to WOT wide open throttle Stop the watch as the speedometer needle sweeps past 20 MPH 32 km hr Several runs should be made to as sure a good average 6 Prop break loose sudden higher if not excessive in some cases can be beneficial dur ing acceleration If undesirable break loose oc curs it can be decreased by trimming the out board further under If it remains excessive with all similar propellers the outboard must be low ered It is suggested that all applicable data be re corded on a chart such as that illustrated follow ing and retained for future reference After several propellers of different pitch and or design have been tried select one that best serves the general purpose of the boat The se lected propeller should enable the engine to op erate within its recommended full throttle RPM range without excessive propeller break loose during acceleration or turns A second propeller that would make both a suitable spare or a spe cial purpose alternate might also be desirable NOTE A higher pitch often gives best top speed but the next lower pitch gives adequate top speed with much better acceleration Boat Test Chart Propeller Diameter Time and in Tine Pepe Pitch 108 x 15 104 x 14 WOT is wide open throttle 90 814676R1 DECEMBER 1996 Water Condition Temperature IMPORTANT INFORMATION 1 7 Lubrication Points
290. isas sembled completely and ALL O rings be re placed Check ball components and castings must be cleaned using engine cleaner and com pressed air or replaced prior to reassembly Support outboard with tilt lock lever when servicing manual tilt system 1 Check manual release cam adjustment Cam must open and close freely Adjust cam link rod as necessary 51143 a Link Rod b Manual Release Lever Accumulator 5F 18 MID SECTION fn 2 Check for external leaks in the manual tilt system Replace defective part s if leak is found IMPORTANT If cut or damaged O rings are found inspect machined surfaces for scoring burrs or debris 3 Check for discharged accumulator 35 to 50 Ib ft 47 68 N m of pulling force must be attained when tilting outboard from full down to full up position If more than 50 Ib ft 68 N m of force is required replace accumulator 50431 a Weight Scale b Valve Lever open position 90 814676R1 DECEMBER 1996 Q Troubleshooting Flow Chart Outboard falls to full down position with manual re lease valve lever in LOCK RUN up position Ex ample a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceleration CAUTION Tilt ram must be in full up position and accu mulator removed before manual tilt system disassembly Inspect memory piston O ring Results Results O ring defect O ring appe
291. iston Tighten piston securely using spanner wrench 1 4 in x 5 16 in long peg a Trim Rod Piston b Spanner Wrench Install lubricated O ring to trim rod piston Install check ball components into its respective bore Secure components in place using plate and screws Torque screws securely Screw Plate O ring Ball Seat Spring Spring MID SECTION 5B 35 Trim Rod Installation 4 Install trim rod into cylinder 1 Place trim cylinder in soft jawed vise 2 Fill trim cylinder three inches 76 2mm from top of cylinder using Quicksilver Power Trim and Steering Fluid or ATF Type FA or Dexron Il 3 Install lubricated O ring to memory piston and place into cylinder Push piston down to level of oil 51196 5 Tighten end cap assembly to cylinder securely using spanner wrench 1 4 in x 5 16 in long pegs 51144 a O ring b Memory Piston IMPORTANT Memory piston must not come in contact with trim rod end cap during end cap trim rod installation 51145 6 Tighten manual release valve snuggly following end cap installation 5B 36 MID SECTION 90 814676R1 DECEMBER 1996 Q Bleeding Power Trim Unit IMPORTANT Manual release valve must be in the closed position during power trim bleeding and operation 1 Secure power trim unit in soft jawed vise 2 Remove fill screw Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmissi
292. k Valve Reassembly Design 1 1 Insert retainer thru plastic disc and rubber check valve b Xe 23601 a Retainer b Plastic Disc Rubber Check Valve 2 Install check valves and retainers into fuel pump bogy 3 8 FUEL SYSTEM AND CARBURETION cM With retainer installed in pump body break re tainer rod from retainer by bending sideways 23601 a Retainer Rod b Retainer 4 Reinstall rod into retainer cap and use a hammer and punch to tap rod down into retainer until flush with top of retainer 23601 a Rod b Retainer Cap 5 Assemble remaining components as shown in Fuel Pump Exploded View preceding Install bolts and torque to 60 Ib in 6 8 52019 a Bolts Torque to 60 Ib in 6 8 N m 90 814676R1 DECEMBER 1996 PAS LE Fuel Pump Installation 3 Connecthoses as shown Secure hoses with sta straps Design 1 1 Install gasket on fuel pump base 52014 a Gasket b Base 2 Install pump and secure with screws Torque screws to 60 Ib in 6 8 a Inlet Hose b Outlet Hose a Screws Torque to 60 Ib in 6 8 N m FUEL SYSTEM AND CARBURETION 3 9 90 814676R1 DECEMBER 1996 Fuel Pump Exploded View Design 2 IMPORTANT Align all gasket and diaphragm aligning tabs with fuel pump aligning tabs during reassembly NOTE Respective diaphragms go against the mat ing surfaces of the fuel pump body a
293. l Cleaner should be applied to the areas of the cylinder bore where transfer of alu minum has occurred After the acidic solution has removed the transferred aluminum thoroughly flush the cylinder bore s to remove any remain ing acid Cylinder walls may now be honed to re move any glaze and to aid in the seating of new piston rings HONING PROCEDURE a When cylinders are to be honed follow the hone manufacturer s recommendations for use of the hone cleaning and lubrication dur ing honing b For best results a continuous flow of honing oil should be pumped into the work area If pumping oil is not practical use an oil can Apply oil generously and frequently on both stones and work CAUTION When honing cylinder block remove hone fre quently and check condition of cylinder walls DO NOT hone any more than absolutely neces sary as hone can remove cylinder wall material rapidly 90 814676R1 DECEMBER 1996 Localize stroking in the smallest diameter un til drill speed is constant throughout length of bore Maintain firm stone pressure against cylinder wall to assure fast stock removal and accurate results Expand stones as neces sary to compensate for stock removal and stone wear Stroke at a rate of 30 complete cycles per minute to produce best crosshatch pattern Use honing oil generously d Thoroughly clean cylinder bores with hot wa ter and detergent Scrub well with a stiff bristle brush and rins
294. l shaft seal in valve block with lips facing out Install cam shaft assembly in valve block Boo mw o Secure cam shaft in place using insulator retain er plate and screw Tighten screw securely a Spacer Retainer Clip b Retainer Clip c Screw d Shaft Seal e O ring f Back up Seal g Cam 90 814676R1 DECEMBER 1996 VALVE BODY CHECK REASSEMBLY 1 Install lubricated O ring plunger steel ball and conical spring to valve block es O b 51145 Conical Spring Steel Ball Plunger O ring VELOCITY VALVE REASSEMBLY 1 Install spool spring lubricated O ring and screw plug surge valve assembly into valve block 2 Torque screw plug to 75 Ib in 8 5 N m b z y d a Spool b Spring c O ring d Screw Plug Torque to 75 Ib in 8 5 MID SECTION 5G 27 e CHECK RETAINER REASSEMBLY Valve Block Installation 1 Install plunger spring large ball spring small 1 Install lubricated O rings and dowel pins and plug into valve block a 51148 b a O rings 2 b Dowel Pins 2 d e 51142 2 Install valve block to shock rod cylinder Insert screws to shock rod cylinder and torque to 100 Ib a Plunger i 11 N b Spring Large in m c Ball d Spring Small e Plug VALVE PLUG REASSEMBLY 1 Install plunger steel ball spring lubricated O ring and screw plug Torque screw plugs to 75 Ib in 8 5 N m
295. l valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to re as sembly IMPORTANT Power trim system is pressurized Outboard must be in the full UP position trim rod fully extended prior to fill drain plug or man ual release valve removal Refer to instructions following if disassembly is re quired when servicing Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks IMPORTANT Operate Power Trim system after each check to see if problem has been corrected If problem has not been corrected proceed to next check 1 Check that manual release valve is tightened to full right clockwise position 2 Check trim pump fluid level with outboard in full UP position and fill if necessary Refer to Bleeding Power Trim Unit 3 Check for external leaks in Power Trim system Replace defective part s if leak is found 4 Outboard not holding tilted position falls down to trim position indicates debris or defective com ponents in trim assembly Clean or replace com ponents as required 5E 20 MID SECTION 90 814676R1 DECEMBER 1996 cM Hydraulic System Troubleshooting Flow Chart OUTBOARD WILL NOT HOLD TILTED POSITION DURING REVERSE AND OR TRAILS OUT DURING HIGH SPEED DECELERATION Manual release valve nspect manual release valve and Oring damaged Clean and reinstall manual rel
296. lamp handles can be secured to the boat transom us ing optional Quicksilver Accessory Outboard Mounting Kit C P N 812432A4 to allow for quick removal and installation of outboard Refer to installation instructions supplied with the mounting kit before drilling any mounting holes in the boat transom Tighten transom clamp han dles when using mounting kit Tighten Transom Clamp Handles Outboard must be fastened to boat transom one of two ways permanently fastened to transom with transom clamp handles and mounting bolts provided or secured to the transom using the optional outboard mounting kit P N 812432A4 should the outboard strike an underwater object or be steered into a sharp turn Failure to fasten outboard correctly to the boat transom with mounting bolts or optional mounting kit could re sult in outboard ejecting suddenly off boat tran som causing serious injury death boat damage or loss of outboard 90 814676R1 DECEMBER 1996 FASTENING OUTBOARD TO THE BOAT TRANSOM IMPORTANT Read the preceding WARNING be fore installing outboard Use a 17 32 inch 13 5mm diameter drill bit and drill two upper mounting holes and two lower mounting holes Position outboard on boat transom Align the mount ing holes in the transom brackets that will place the outboard nearest to the recommended mounting height Apply marine sealer to shanks of mounting bolts not threads and secure outboard to transom with 4
297. lay p guess Power Trim Motor Engine Harness BLU WHT GRN WHT RED Rectifier StartSolenoid S To Battery Trim Relays 51507 5D 10 MID SECTION 90 814676R1 DECEMBER 1996 c Troubleshooting Down Circuit When Up Circuit is OK Remote Control Not Equipped with Trailer Button Connect Voltmeter red lead to Point 1 and black lead to ground Depress the Down trim button Battery Voltage Indicated No Voltage Indicated Down Relay is Defective Replace and retest Connect Voltmeter red lead to Point 4 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 4 and 1 No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 90 814676R1 DECEMBER 1996 MID SECTION 5D 11 Troubleshooting Up Circuit When Down Circuit Is OK Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground Depress the Up trim button Battery Voltage Indicated UP Relay is defective Replace and retest No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If n
298. leshooting Sequence Chart Engines with Black Stator Start the ignition troubleshooting by first performing Step 1 then continue the series of steps to locate the problem Refer to the troubleshooting steps on the following pages Low or No Voltage at two coils Eu L No Voltage at all coil Primary Voltage At The Ignition Coils Test Go To Low or No Voltage at one coil Step 3 Test for Spark Good Voltage at all coils Page 2A 11 DVA TESTS 9 AMP BLACK STATOR p Ex ems DVA TESTS 16 AMP BLACK STATOR 398 9710A33 amp 398 9710A42 om 0 Bw Sw Red Sw Stator High Speed 400 VDC Box Term Ground 8 10 27 33 165 205 20 VDC White Black Switch Box Bias or Ground Switch Box 2 10 10 30 10 30 40 VDC Terminal f using a meter with a built in DVA place selector switch in the DVA 400 VDC position 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2 3 gt Ignition Troubleshooting Engines With Black Stator STEP 1 Primary Voltage At The Ignition Coils Test TEST RESULTS No voltage output or low voltage output on all coils Go to STEP 2 Stop Circuit Test Good voltage on two coils Go to Trigger Test Good voltage on all coils Go to Testing For Spark 1 Use Multimeter DVA Tester 91 99750 2 Crankengine and observe meter reading IGNITION VOLTAGE 9 AMP STATOR Selector
299. leshooting the starter circuit This flow chart will accurately locate any existing malfunction Location of Test Points called out in flow chart on next page are numbered below STARTER SOLENOID 89 68258 STARTER f 1 7 STARTER SOLENOID J BLACK LR YELLOW FAA BLACK YELLOW RED YELLOW RED NEUTRAL START SWITCH LOCATED IN CONTROL HOUSING 90 814676R1 DECEMBER 1996 cM Starter Circuit Troubleshooting Flow Chart Starter Motor Does Not Turn SAFETY WARNING Disconnect yellow starter motor cable from starter solenoid test Point 1 BEFORE making tests 1 thru 7 to prevent unexpected engine cranking TEST 1 Use an ohmmeter R x 1 scale and connect meter leads between negative battery post and common powerhead ground No Continuity Indicated Continuity Indicated There is an open circuit in the black negative battery cable Proceed to TEST 2 between the negative battery post and the powerhead a Check cable for loose or corroded connections b Check cable for open circuit TEST2 12 Volt Reading No voltage reading a Disconnect black ground wire from Test Point 2 Check black ground wire for poor proceed to TEST 3 b Connect voltmeter between common engine connection or open circuit reconnect ground and Test Point 2 mE ground wire to starter solen
300. ling Main Bearing Race on Crankshaft 4 32 POWERHEAD 54712 a Snap Ring b Outer race Main Bearing Installed 3 Install main bearing support onto main bearing race Locating pin must enter hole in main bear ing race b 54713 a Locating Pin Position in Main Bearing Race b Alignment Pins 2 Required 90 814676R1 DECEMBER 1996 Cn 4 Secure both halves of each main bearing race together with two bolts Torque bolts to 80 Ib in 9 0 N m 6 Secure both halves of reed block together with two screws and nuts Torque reed block screws to 55 Ib in 6 2 N m ux Um l b Bolts Torque to 80 Ib in 9 0 N m Locating Pin IMPORTANT Check reed stop setting for proper opening Larger opening can cause reed break age smaller opening will not allow sufficient air fuel mixture to enter at higher RPM NOTE Either side of reed block can be facing up 5 Lubricate inner bore of reed blocks with Light Oil and install onto crankshaft D SSS SS LA O Ne gt a Lubricate Inner Bore with Light Oil b Insert Locating Pins into
301. ll shift lever plate and bushing into mid sec tion as shown Shift lever plate must face forward while gearcase is in neutral position a Shift Lever Plate 90 814676R1 DECEMBER 1996 7 Install shift linkage to bottom cowl as shown T S m wo E IR 28 54634 Shift Lever Plate Shift Link Slider Retainer Install power head refer to Section 4 MID SECTION 5A 7 cM MID SECTION POWER TRIM DESIGN 1 Table of Contents Page Power Trim General Information 5B 1 Descrplloli doro 5B 1 Trimming Characteristics 5B 1 Trimming Outboard Up Out 5B 1 Trimming OUtboard Down In 5B 1 Trailering Outboard 5B 2 Tilting Outboard Up and Down Manually 5B 2 Trim In Angle Adjustment 5B 2 Power Trim System Components 5B 3 Torque Specifications 5B 3 Quicksilver Lubricants and Service Aids 5B 3 Power Trim Flow Diagrams Design 1 5B 4 Determine if Problem is Electrical or Hydraul iios sunt ehe DE RSS 5B 11 Trouble Chart 5B 11 Hydraulic System Troubleshooting 5B 12 Preliminary Checks 5B 12 Leak Down Check Pump and Manifold Assembly 5B 12 Leak Down
302. ller handle Turn conduit in until bottomed out on tiller handle then back off one turn 54820 8 Reinstall cable guide to throttle cable o a 54819 a Screws b Cable Guide Throttle Cable 90 814676R1 DECEMBER 1996 p i Tiller Handle Installation 3 Secure tiller handle assembly to studs of out board steering arm using tab washers a and ELECTRIC START MODEL SHOWN locknuts b Torque locknuts to 33 Ib ft 45 N m 1 Insert shift link rod b thru opening in the bottom and bend tab washers against hex of locknuts cowl 0505 2 Route shift link rod a around port side of out board and position through lower opening in rub 54828 ber grommet b 54827 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7B 5 Shift Link Rod Installation 1 Place shift lever located on tiller handle in Neutral position CAUTION To avoid accidental starting which could result in personal injury remove and isolate high ten sion spark plug leads from spark plugs before working near propeller 2 Place engine shift actuating slide to neutral posi tion propeller turns freely in both directions 3 Adjust shift link rod a to fit over peg b of shift actuating slide without moving shift lever or actu ating slide 4 Secure shift link rod end a onto shift peg using rod end reta
303. llowing a Motor Wire Black b Motor Wire Orange MOTOR DISASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated 51193 If full continuity is not indicated clean switch contact surfaces using an ignition point file Recheck switch if full continuity is not indicated re place end frame MID SECTION 5B 29 cM Armature Tests Power Trim System TEST FOR SHORTS Reassembly Check armature on a Growler follow Growler man ufacturer s test instructions Indication of a short re Manifold Installation quires replacement of armature IMPORTANT Filter must be installed in trim cylin TEST FOR GROUND der with ridge of filter housing facing out Use an Ohmmeter R x 1 scale Place one lead of Ohmmeter on armature shaft and other lead on com mutator as shown If continuity is indicated armature is grounded and must be replaced 50447 1 Install lubricated O rings and filter with housing ridge facing out to trim cylinder 51195 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down on an armature conditioner tool or on a lathe Clean commutator with 00 sandpaper SEM SS tms ER c b Filters 5B 30 MID SECTION 90 814676R1 DECEMBER 1996 p i 2 Install check ball components a into manifold 54744 3 Hold check ball compon
304. locknut to 20 Ib ft 27 50568 b Position attaching kit on transom so that tran som bracket is centered on the 15 in line Figure 1 at a height where the center of Ride Guide yoke is even with or not more than 1 2 in 12 8mm above top edge of transom Figure 3 50568 Transom Backing Plate Bolt 5 16 in x 3 1 4 in Locknut Torque to 10 Ib ft Ride Guide Yoke Attaching Locknut Torque to 10 Ib ft Then Back Off 1 4 Turn 2 3 8 in Maximum Transom Thickness Bolt 7 16 in x 1 3 4 in Ride Guide Yoke igure 2 Installing Attaching Kit OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 15 NOTE When arilling thru transom be sure that holes are drilled perpendicular to transom 6 With attaching kit positioned as outlined preced ing use 3 holes in transom bracket as a guide and drill three 11 32 in 8 7mm holes thru tran som Se BEN D 594 Ride Guide Yoke to 1 2 in Center of Ride Guide Yoke to of Tran som Top of Transom Transom Bracket Cable Tube Jam Nuts Torque to 35 Ib ft 41 5 N m Tab Washer After Jam Nuts are Torqued to Specification Bend Locking Tabs Against Nuts h Cable Guide Tube i Ride Guide Cable Attaching Nut Torque to 35 Ib ft 41 5 N m Kit Clevis Attaching Locknut Torque to 20 Ib ft 27 1 N m Figure 3 Installing Attaching Kit o
305. luid from the up cavity forced into the accumu lator c will cause the internal accumulator piston d to compress the gas With the engine in the correct position the camshaft lever is rotated up and the push rods allow the check valves e h amp j to close 90 814676R1 DECEMBER 1996 MID SECTION 5G 7 Shock Rod b End Cap Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 8 MID SECTION Slow Tilt Down Under High Thrust Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston Shock Return Valve p Impact Relief Valve 90 814676R1 DECEMBER 1996 c Slow Down Under Thrust To tilt the engine down under high thrust conditions where the propeller thrust forces the shock rod down creating higher pressure below the memory piston m the camshaft lever f is rotated slightly downward The internal shaft connected to the lever will open the down slow transfer valve i allowing oil under pressure into the cavity around the shaft The higher oil pressure will open the up fast transfer valve j allowing oil from the bottom of the cylinder to flow above the shock piston n while lowering the engine Additional oil will flow into the accumulator c as the internal pressure forces the accumulator check valve e to ope
306. lve block 3 Secure cam shaft in place using insulator retain er plate and screw Tighten screw securely 5F 28 MID SECTION KR 51142 Screw Retainer Plate Insulator Cam Shaft O ring Install push rod ball flat spring and screw in valve block Torque screw to 27 lb in 3 0 N m 51145 Screw Flat Spring Ball Push Rod 90 814676R1 DECEMBER 1996 6 Install spool spring lubricated O ring and screw plug surge valve assembly into valve block 7 Torque screw plug to 75 Ib in 8 5 N m 51142 a Plunger b Ball c Spring Small d Spring Large e O ring o gt 51142 f Plug Design 3 a Spool 12 Torque screw plug to 75 Ib in 8 5 N m b Spring c O ring d Screw Plug 8 Install push rod ball spring lubricated O rings and screw plug transfer valve components in valve block 9 Install plunger ball spring small spring large in valve block Slow Trim Valve Assembly 10 Apply Loctite Pipe Sealant with Teflon 592 to threads of pipe plug design one and two style valve block 11 Install pipe plug or plug into valve block Tighten pipe plug if equipped securely Push Rod 2 Ball 2 Spring 2 O ring 2 screw Plug 2 90 814676R1 DECEMBER 1996 MID SECTION 5F 29 Valve Block Installation 1 Install lubricated O rings 51148 a O rings 2
307. lve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly Clean shock and components with compressed air DECEMBER 1996 10 Remove inner O ring 51199 a Shock Piston b O ring 11 12 13 14 Remove cylinder end cap assembly from shock rod Inspect shock If wiper located in cap has failed to keep rod clean replace wiper Place end cap on clean work surface Remove rod wiper inner O ring and outer O ring 51147 51145 a Rod Wiper b Inner O ring Outer O ring MID SECTION 5G 21 Valve Block Removal 1 Remove two screws from the shock rod cylinder to separate the valve block 51146 Screws 2 Shock Rod Cylinder 2 Remove O rings and dowel pins 51148 a O ring 2 b Dowel Pin 2 5G 22 MID SECTION 1 Remove memory piston from cylinder using one of two methods Memory Piston Removal a Using lock ring pliers Craftsman P N 4735 or Snap on P N SRP4 LOCK RING PLIERS gt 2 b Blowing compressed air into center O ring hole Memory piston cup may be expelled at a high velocity when air pressure is applied Failure to place cylinder as shown below could result in personal injury 51144 NOTE Point cylinder opening down and away Use a shop rag or towel to avoid damage to the memory piston Fluid will blow out also a Adaptor Air H
308. mm Firing Order 1 3 2 4 90 814676R1 DECEMBER 1996 Special Tools Part Number Flywheel Holder 91 52344 Flywheel Holder Strap 91 24937 1 Wrench Piston Ring Compres 91 31461 2 sor Bearing Puller 91 24100A1 Powerhead Stand 91 25821A1 Torque Wrench 0 200 Ib ft Torque Wrench 0 150 91 66274 Ib in Compression Tester 91 29287 May be Obtained Locally 91 32610 General Information Powerhead Disassembly and Reassembly instructions are printed in a sequence that should be followed to assure best results when removing or re placing powerhead components If complete disas sembly is not necessary start reassembly at point where disassembly was stopped Refer to Table of Contents preceding Usually complete disassem bly of powerhead will be required If major power head repairs are to be performed remove power head from drive shaft housing Removal of powerhead is not required for minor repairs on com ponents such as ignition system carburetors etc POWERHEAD 4 1 Throttle Control Linkage 30 29 BLA L Tec OS 2 4 C With Teflon 92 825407A12 4 2 POWERHEAD 90 814676R1 DECEMBER 1996 Throttle Control Linkage TORQUE QTY DESCRIPTION Ib in Ib ft 1 BRACKET SCREW 1 1 8 IN LOCKWASHER THROTTLE ACTUATOR LINK ROD SWIVEL BALL SWIVEL BASE NUT By cnm Drive
309. move securing fuel line connector to bot tom cowl 54669 a Bolt b Fuel Line Connector 4 12 POWERHEAD c NOTE If oil tank contains oil inlet hose to oil pump must be plugged when disconnected to prevent oil leakage 11 Remove inlet hose from oil pump 53119 a Inlet Hose b Oil Pump 12 Remove black lead from grounding bolt at aft starboard corner of bottom cowl 13 Remove tell tale hose from bottom cowl 54670 a Black Lead b Grounding Bolt Tell Tale Hose 90 814676R1 DECEMBER 1996 14 Remove three bolts securing flywheel cover to powerhead and remove cover and oil tank assembly NOTE Hold oil tank securely when removing from powerhead as oil tank may detach from flywheel cover assembly a Bolts b Flywheel Cover 15 Remove four bolts securing trim cover to bottom cowl and remove cover 54671 a Bolts 2 Each Side b Trim Cover 90 814676R1 DECEMBER 1996 16 Remove eight nuts securing powerhead to drive shaft housing 54672 a Nuts 4 Each Side 17 Remove plastic cap from center of flywheel and thread Lifting Eye 91 75132 into flywheel Us ing hoist lift powerhead from driveshaft housing and install on Powerhead Stand 91 25821 1 or work bench
310. move crankshaft assembly from cylinder 12 Remove 6 screws securing transfer cover to cyl block If pry bar is used to aid in removal of crank inder block and remove cover shaft assembly pad surface of block where pry 13 Remove balance tube and fittings from cylinder bar contacts block 7 14 Remove bleed hose and bleed check valve from cylinder block 15 Remove tell tale hose and fitting from cylinder block 5 NOTE Manual Start Models and some early Electric S v Start Models have fuel enrichment fitting in the bal ance tube eH Alle e Os Z E 54690 a Crankshaft Assembly b Pry Bar c Pad Screws Transfer Cover Balance Tube Bleed Hose Bleed Check Valve T Fitting Fuel Enrichment 90 814676R1 DECEMBER 1996 POWERHEAD 4 19 x 16 Remove 10 bolts from cylinder block cover 17 Remove 15 bolts from exhaust manifold cover remove cover Remove temperature switch from and remove manifold cover and baffle plate from cylinder block cylinder block 5 D 4 201 FS Pd So d D 19 9
311. mperature of the air its barometric pressure and water vapor or humidity content Accompanying this weather inspired loss of power is a second but more subtle loss At rigging time in early spring the engine was equipped with a propeller that allowed the engine to turn within its recommended RPM range at full throttle With the coming of the summer weather and the consequent drop in avail able horsepower this propeller will in effect become too large Consequently the engine operates at less than its recommended RPM Due to the horsepower RPM characteristics of an en gine this will result in further loss of horsepower at the propeller with another decrease in boat speed This secondary loss however can be regained by switching to a smaller pitch propeller that allows the engine to again run at recommended RPM For boaters to realize optimum engine performance under changing weather conditions it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the en gine also will be operating in an RPM range that dis courages damaging detonation This of course en hances overall reliability and durability of the engine 90 814676R1 DECEMBER 1996 Q Conditions Affecting Operation 1 Proper positioning of the weig
312. n Check for voltage at any instru ment using a Voltmeter No Voltage Indicated Red wire is open between Point 3 and red terminal on back of the ig nition switch Check for loose or corroded con nections Check for open circuit in wire 90 814676R1 DECEMBER 1996 Battery Voltage Indicated Trim switch is faulty or there is an open circuit in wires green white blue white between trim buttons and trim pump Check trim switch Check all trim harness connec tors for loose or corroded con nections Check for pinched or severed wires Battery Voltage Indicated There is an open circuit in wire be tween Point 5 and Red terminal on the back of the ignition switch MID SECTION 5D 13 x 1 Power Trim System Removal Inspect cross pin hole and pivot pin hole for damage 6 Usesuitable punch to remove DRIVE UP lower dowel pin Retain dowel pin Support outboard with tilt lock lever when servicing power trim system 1 Disconnect power trim harness from outboard wiring harness 2 Remove screw and clip securing wiring harness to clamp bracket 3 Remove trim gauge sender if equipped Use suitable tool to remove upper headed cross pin Retain pin Straight pin is hard to remove see item 5 51144 Cross Pin 7 Use suitable punch to drive out lower pivot pin a Cross Pin Design 1 Straight b Cross Pin Design 2 Headed 5 Drive out upper pivot p
313. n 406mm This kit contains all necessary parts to connect both outboards to Ride Guide Steering Cable for 21 in b33mm MINIMUM thru 22 1 2 in 672mm If out board centerline distance is other then specified re fer to Ride Guide Steering Attachment Extension Couplers following Ride Guide steering cable can be routed on either side of boat If steering cable is routed on starboard side of boat install steering cable to outboard mounted on port side of boat or if steering cable is routed on port side of boat install steering cable to outboard mounted on starboard side of boat Refer to Steering Cable Installation Starboard Outboard following Refer to Quicksilver Accessories Guide to deter mine correct length of steering cable and remote con trol cables IMPORTANT Steering cable and remote control cables MUST BE THE CORRECT LENGTH sharp bends too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables Install steering mount and steering wheel in accor dance with installation instructions that accompany each 90 814676R1 DECEMBER 1996 c Steering Cable Installation Cable Routed Down Starboard Side of Boat to Port Outboard IMPORTANT Before installing steering cable into tilt tube lubricate entire cable end with Quicksilver 2 4 C Marine Lubricant NOTE Ride Guide Steering cable is lubricated at the fa
314. n e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 14 MID SECTION Shock Function Return Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston Shock Return Valve p Impact Relief Valve 90 814676R1 DECEMBER 1996 PAS Shock Function Return After the drive clears the object the shock return valve o will allow the oil to flow from between the shock piston n and memory piston m onto the down cavity as the drive returns to its original running position 90 814676R1 DECEMBER 1996 MID SECTION 5G 15 Hydraulic System Troubleshooting Refer to disassembly reassembly instructions fol lowing if disassembly is required when servicing IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball components and castings must be cleaned using engine cleaner and com pressed air or replaced prior to reassembly Support outboard with tilt lock lever when servicing manual tilt system 1 Check manual release cam adjustment Cam must open and close freely Adjust cam link rod as necessary a Link Rod b Manual Release Lever Accumulator 2 Checkfor external leaks in the manual tilt system Replace defective part s if leak is found
315. n Oil flowing into the accumulator moves the accumulator piston d and compresses the gas 90 814676R1 DECEMBER 1996 MID SECTION 5G 9 Shock Rod b End Cap Accumulator d Accumulator Piston e Accumulator Check Valve f Camshaft Lever g Manifold h Down Fast Transfer Valve 5G 10 MID SECTION Under Water Strike Valves Open Down Slow Transfer Valve j Up Fast Transfer Valve k Surge Valve Cylinder m Memory Piston n Shock Piston Shock Return Valve p Impact Relief Valve 90 814676R1 DECEMBER 1996 c Under Water Strike With Valves Open Should the drive unit strike a submerged object while in forward motion the shock rod a will extend from the tilt cylinder 1 Fluid will attemptto exit the cylinder through the interconnecting passage The rapid fluid flow will increase the pressure below the surge valve K causing the valve to move closing the oil return passage back into the accumulator c Oil inside the up cavity is locked in a static position by the closed up fast transfer valve j the closed down slow trans fer valve i and down fast transfer valve h As the shock rod extends outward the pressure inside the up cavity will reach sufficient pressure to open the shock valve p which opens at 880 1110 psi will flow into the cavity created as the shock rod amp shock piston a amp n moves away from the memory piston m 90
316. n must be used with this outboard This warning horn is neces sary for both the oil injection warning system and the engine overheat warning system BOATS EQUIPPED WITH PANEL OR CONSOLE MOUNT REMOTE CONTROL A Quicksilver Ignition Key Choke Assembly equipped with a warning horn is necessary for both the oil injection warning system and the engine over heat warning system 90 814676R1 DECEMBER 1996 Oil Injection System Troubleshooting NOTE There is a safety reserve of oil left in the oil Chart tank after the low oil warning is sounded that allows you enough oil for approximately 30 minutes of full throttle operation TROUBLESHOOTING THE OIL INJECTION SYSTEM 2 there is more than approximately 7 5 fl oz T 225ml of oil remaining in the oil tank then the If a problem occurs with the oil injection system and problem may be a faulty low oil warning sensor or the warning horn sounds in a pulsating manner stop afaulty warning module Refer to troubleshooting engine and check if problem is caused by 1 low oil chart following level or 2 a faulty warning sensor or module 1 Check oil level in oil tank If oil level is approxi mately 7 5 fl oz 225ml or less the problem is low oil level Add oil to oil tank TROUBLESHOOTING CHART Problem Warning Horn Does Not Sound when Ignition Key is Turned to ON Position Possible Cause Corrective Action Horn malfunction or open tan blue wire between Disconnect t
317. n Valve t Memory Piston i Up Circuit Suction Port u Shock Piston Oil Pump v Impact Relief Valve k Down Circuit Suction Port w Cylinder Oil Fill Cap 5E 16 MID SECTION 90 814676R1 DECEMBER 1996 Shock Function Return After the engine clears the under water object the weight of the engine will increase the oil pressure be tween the memory piston t and shock piston u to the level required to open the shock return valve h inside the shock piston allowing the oil to bleed back through the shock piston into the down cavity If re quired additional oil will enter the down cavity through the manifold reverse suction valve o This will return the engine back against the memory piston t and into the original running position 90 814676R1 DECEMBER 1996 MID SECTION 5E 17 4 Down Pressure 525 880 PS cM MANUAL RELEASE Reservoir ul Return Oil zl Filtered Impact R elief P ressure 22 Up Pressure 1625 40 60 2800 75 125 min Piston Rod End Cap Electric Motor Reservoir Oil Down Pressure Regulating Valve Down Pressure
318. n as follows a Slowly pull starter rope outward Pawl must move to engage position as the lever begins to turn 2 Using a screwdriver a turn sheave shaft coun terclockwise to pull knot in rope against rope guide b Extend starter rope to full length and allow it to slowly rewind must rewind smoothly with out catching 3 With rope knot against rope guide turn sheave shaft 2 full turns counterclockwise to add proper tension to rewind spring If starter rope catches and fails to rewind smoothly the sheave shaft and washers are not correctly aligned 4 Position tab of tab washer over holes in rewind assembly 5 While holding sheave shaft as described in step 2 tighten sheave shaft retaining nut b N Bend 2 tabs a of tab washer against flats of retaining nut and 2 tabs b into holes in rewind housing as shown a Hold Retainer Nut and Turn Sheave Shaft 2 Full Turns to Add Proper Tension to Rewind Spring b Sheave Shaft Retaining Nut Left hand Thread Turn Counterclockwise to Tighten 54860 54861 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7 7 8 Install rewind starter on engine with 3 screws 10 Pull starter rope thru cowl panel and 6 lockwashers Torque to 100 Ib in 11 N m dle and rope retainer 9 Install and adjust shift interlock cable as outlined 11 Reinstall removed cowling in Shift Interlock Adjustment Section 7B 54862
319. n assembly Clean trim rod and components with parts cleaner and dry with compressed air It is recommended that all O rings in trim system be replaced Inspect trim rod If scraper located in cap has failed to keep rod clean replace scraper Lubricate all O rings using Quicksilver Power Trim and Steering Fluid or ATF F FA or Dexron Il Motor and Electrical Tests Repair Trim Pump Motor Test Do not perform this test near flammables or ex plosives as a spark may occur when making connections 1 Disconnect orange motor wire and black mo tor wire from relay switch wiring harness 2 Connect a 12 volt power supply to motor wires positive to orange negative to black results in motor up direction Positive to black negative to orange results in motor down direction Motor should run 3 If motor does not run disassemble motor and check components Thermal Overload Switch Test IMPORTANT If thermal overload switch has been activated pump motor cannot be tested for a minimum of one minute After this period switch should close reset itself and pump motor may be operated Perform the following check s only if switch does not reset itself 90 814676R1 DECEMBER 1996 MOTOR ASSEMBLED Connect Ohmmeter R x 1 scale leads as shown If switch is good full continuity zero ohms will be indi cated If full continuity is not indicated disassemble motor and recheck switch per instructions fo
320. n salt water area is considered Severe Service 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifications NOTE Ride Guide Steering cables are lubricated at the factory and requires no additional lubrication at initial installation Core of each steering cable transom end must be fully retracted into cable housing before lubri cating cable If cable is lubricated while ex tended hydraulic lock of cable could occur 3 With core of Ride Guide Steering cable transom end fully retracted lubricate transom end of steering cable thru grease fittings a with 2 4 C Marine Lubricant Lubricate exposed portions of cable ends b with 2 4 C Marine Lubricant 4 Lubricate pivot points of steering link rods and ball joints of link rods steering coupler with Quick silver 2 4 C Lubricant 5 Inspection and lubrication of steering head as sembly rotary or straight rack should be per formed once each year by your Authorized Deal er or whenever steering mount and or steering head are disassembled or if steering effort has increased Lubricate with 2 4 C Marine Lubri cant 90 814676R1 DECEMBER 1996 x Transom Mounted Ride Guide Attaching Kit Installation 73770A1 Attaching Kit Installation 1 b G f g h k Lubricate both holes in pivot block Figure 1 wi
321. nd piston rings were installed in powerhead break in procedures MUST BE followed Refer to OWNERS MANUAL for specific break in instruc tions When initially priming carburetors with fuel us ing the fuel line primer bulb inspect all fuel hose con nections for signs of fuel leakage 90 814676R1 DECEMBER 1996 POWERHEAD 4 49 MID SECTION CLAMP SWIVEL BRACKET AND DRIVE SHAFT HOUSING Table of Contents Swivel Bracket Components Torque Specifications Quicksilver Lubricants and Service PIGS Transom Bracket Components Torque Specifications Quicksilver Lubricants and Service Di PRU Drive Shaft Housing Components Torque Specifications Quicksilver Lubricants and Service AdS 5 de rac agi RR Disassembly Reassembly Tilt Lock Lever Transom Bracket Drive Shaft HOUSING eer e 90 814676R1 DECEMBER 1996 wivel Bracket Components Bumper Steering Arm Lock Nut Steering Bracket Locking Plate Bolt 2 Bolt Steering Arm 2 Steering Link Bolt 10 Washer Upper 11 Washer Lower 12 Lock Nut 13 Washer 2 14 Oil Seal 2 Seal Lip Outward 15 Bushing Swivel Pin 2 16 Bushing Swivel Bracket 17 Swivel Bracket 18 Grease Fitting 19 Yoke 20 Retaining Rin
322. nd respective gaskets are between the diaphragms and end caps Gaskets should always be replaced on fuel pump reassembly Fuel Pump Body Rubber Check Valve Plastic Disc Retainer Spring Cap Diaphragm Boost Chamber Gasket Chamber Plate 10 Pulse Chamber Gasket 11 Fuel Pump Base 12 Base Gasket 3 10 FUEL SYSTEM AND CARBURETION 90 814676R1 DECEMBER 1996 Cleaning and Inspection 1 Clean fuel pump housing chamber plate and pump base then dry with compressed air Inspect spring coils for damage Inspect pump body chamber plate and pump base for cracks or rough gasket surfaces Inspect hoses for looseness or signs of leakage 5 Inspect check valve discs for cracks tears or oth er damage Check Valve Reassembly Design 2 1 Insert retainer thru plastic disc and rubber check valve 5 51530 Retainer b Plastic Disc c Check Valve 2 Install check valves and retainers into fuel pump body 51530 90 814676R1 DECEMBER 1996 3 Break rod from retainer cap and reinstall rod into cap Using a hammer and punch tap rod down into retainer until flush with top of retainer 51530 a Rod b Retainer Cap Fuel Pump Installation Design 2 51518 Fuel Pump Plug Apply PERFECT SEAL 92 34227 1 to threads Inlet Hose Outlet Hose Gasket Cylinder Block to Fuel Pump HIDDEN Screws Torque to 55 I
323. nd tighten locknut on bolt The bar rel must be free to pivot Shift Cable Shift Cam Barrel Roller accom Recheck the shift cable adjustment in forward shift position The correct shift adjustment will position the cam far enough on the roller in order to lock the the reverse gate into forward position You should not be able to forcibly push up the re verse gate toward neutral Pull on the reverse gate by hand to verify this IMPORTANT The forward locking of the reverse gate must be met If not readjust the shift cable LOWER UNIT 6B 7 Lubricating The Drive Shaft Bearing Recommended Lubrication Use Quicksilver 2 4 w Teflon or Lubriplate 630 AA Grease IMPORTANT It is important that you do not use general all purpose grease for this bearing The lubricant we recommend is a water resistant grease of the proper consistency for this applica tion If you use a substitute grease be sure that it is water resistant and of the same consistency Frequency of lubrication We recommend lubricat ing the drive shaft bearing after each day s use and after every 10 hours of operation After every 30 hours of operation pump in extra grease to purge out any moisture a Vent Hose b Grease Gun C Grease Exiting Vent Hose Lubricating Procedure Pull vent hose off the grease fitting Pump in grease through the grease fit ting using the grease gun provided until excess grease starts to e
324. nect wires to proper terminals Refer to c Sta Strap wiring diagrams Section 2D Torque terminal NOTE Stator wiring is routed behind starter motor nuts to 30 Ib in 3 4 N m and enters electrical box through access holes under 5 Reinstall electrical box access cover warning module EE Reinstall flywheel as outlined in FLYWHEEL RE MOVAL AND INSTALLATION preceding 7 manual start models reinstall rewind starter On electric models reinstall flywheel cover On either manual or electric models rewind or cover attaching bolts should be torqued to 100 Ib in 11 3 N m 8 Reinstall top cowl 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2A 17 c Red Stator Installation 3 Install adapter module routing adapter wires 7 through opening in upper right corner of electrical 1 Position stator on powerhead as shown Secure box Connect stator adapter module and switch stator with 4 screws Apply Loctite 271 to screw box wires per appropriate model wiring diagram threads Torque screws to 35 Ib in 4 0 in Section 2D Wiring Diagrams eL x LT IARE C Lja N a Stator T Ib in 4 0 _ 2 a Upper Right Corner b Adapter Module 2 Install BLUE and BLUE WHITE cable adap
325. ned left Check steering thru full range left and right at all tilt angles to assure interference free movement Maintenance Instructions Maintenance inspection is the owner s responsibility and must be performed at intervals specified Normal Service Every 50 hours of operation or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation in salt water is considered Severe Service 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifications NOTE Ride Guide Steering cable is lubricated at the factory and requires no additional lubrication at initial installation Core of steering cable transom end must be ful ly retracted into cable housing before lubricating cable If cable is lubricated while extended hy draulic lock of cable could occur 3 With core of Ride Guide Steering cable transom end fully retracted lubricate transom end of steering cable thru grease fitting and exposed portion of cable end with 2 4 C Marine Lubricant Lubricate all pivot points with SAE 30W engine oil OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 11 Steering Coupler Assembly Position outboards so that they are facing straight forward Distance between threaded hole centers of steering arms brackets MUST BE equal to distance between propeller shaft
326. ness Let dry flash off for five minutes and apply another even coat of one half to one mil film thick ness This urethane paint will dry to the touch in a matter of hours but will remain sensitive to scratches and abrasions for a few days 9 The type of spray gun used will determine the proper reduction ratio of the paint IMPORTANT Do not paint sacrificial zinc trim tab or zinc anode 10 Cut out a cardboard plug for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing IMPORTANT INFORMATION 1 17 Decal Application Decal Removal 1 Mark decal location before removal to assure proper alignment of new decal 2 Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal 3 Clean decal contact area with a 1 1 mixture of iso propyl alcohol and water 4 Thoroughly dry decal contact area and check for a completely cleaned surface Instructions for Wet Application NOTE The following decal installation instructions are provided for a Wet installation decals should be applied wet TOOLS REQUIRED 1 Plastic Squeegee 2 Stick Pin 3 Dish Washing Liquid Detergent without am Joy and Drift are known to be com patible for this process Automotive Body Filler Squeegee Do not use a soap that contains petroleum based solvents SERVICE TIP Placement of decals using th
327. ng Do Not Tighten At This Time b Spacer 21 32 in Long 90 814676R1 DECEMBER 1996 8 Rotate the shift cable retainer so that the set screw is facing out and the slot is facing up 9 Slide shift cable into retainer until brass tube ex tends out 3 3 4 95 mm Secure the retainer atthis position by tightening the set screw until its snug then add an additional 1 8 turn 10 Install the Allen head screw and tighten securely 3 3 4 in Shift Cable Retainer Set Screw Lock Washer Allen Head Screw Tighten Securely 11 Install the shift slider onto the end of the shift cable Tighten locknut then back off 1 4 turn 12 Fasten the rod end retainer with retaining ring m n Retaining Ring Shift Slider Rod End Retainer Stud Bushing Shift Cable Locknut Tighten Then Back Off The Locknut 1 4 Turn LOWER UNIT 6B 17 13 Fasten the anchor plate to the shift cable retainer IMPORTANT Do not over tighten Shift cable re tainer must be free to pivot a Anchor Plate b Locknut Tighten Then Back Off The Locknut 1 4 Turn 14 Lubricate the shift slider rail in the bottom cowl with Quicksilver 2 4 C Multipurpose Lubricant with Teflon 15 Place the shift slider on the rail and fasten the an chor plate to the engine Torque bolts to 200 Ib in 22 6
328. ngine fails to start determine cause fuel electrical or mechanical Engine should be run within 2 hours after recovery of outboard from water as serious internal damage may occur If unable to start engine in this period disassemble engine and clean all parts and apply oil as soon as possible 90 814676R1 DECEMBER 1996 Out of Season Outboard Storage As a safety precaution when boat is in storage remove positive battery cable This will elimi nate possibility of accidental starting of engine and resultant overheating and damage to engine from lack of water In preparing an outboard for out of season storage 2 precautions must be considered 1 The engine must be protected from physical damage and 2 the engine must be protected from rust corrosion and dirt 1 Remove cowling from engine 2 Place outboard in water or install Quicksilver Flushing Attachment over water intake by follow ing instructions outlined in Flushing Outboard see Table of Contents 3 Start engine and allow to warm up Disconnect fuel line and allow engine to run at low RPM while inducing approximately 2 oz 57 g of Quicksilver Storage Seal into each carburetor throat Allow engine to stall out indicating that carburetors have run dry 4 Remove spark plugs from engine and spray approximately one ounce 30ml of Quicksilver Storage Seal into each spark plug hole Manually turn engine over several times to distribute Stor age
329. nifold Removal 5E 30 Shock Rod Removal 5E 30 Shock Rod Disassembly 5E 31 Memory Piston Removal 5E 33 Cleaning Inspection Repair 5E 34 Trim Motor Electrical Tests 5E 34 Reassembly 5E 35 O Ring and Seal Placement 5E 35 O ring Sizes 5E 36 O ring Description and 51265 5E 37 Power Trim Reassembly 5E 38 Shock Rod Reassembly 5E 38 Shock Rod Installation 5E 39 Trim Limit Assembly Installation 5E 40 Manual Release Valve Installation 5E 40 Manifold Installation 5E 40 Oil Pump Installation 5E 41 Pressure Operated Assembly Installation 5E 42 Reservoir Motor Installation 5E 42 Bleeding Power Trim Unit 5E 43 Installation of Power Trim System 5E 43 90 814676R1 DECEMBER 1996 c Special Tools 1 Spanner Wrench P N 91 74951 2 Lock Ring Pliers P N 91 822778A3 LOCK RING PLIERS OD gt I 3 Expanding Rod P N CG 41 11 IU 4 Collet P N CG 41 14 Ex 90 814676R1 DECEMBER 1996 MID SECTION 5E 1 POWER TRIM COMPONENTS B 7 1 Loctite 271 92 809820 2 4 C With Teflon 92 825407A12 NOTE
330. njunction with the recommended Quicksilver tiller handle kit Install tiller handle kit except shift cable connection and adjustment using instructions provided with kit 1 Drill hole in bottom cowl for cable routing as fol lows a Locate the centerlines for the hole following the dimensions given in the illustration below Use a center punch to mark center of hole b Drilla 1 4 in pilot hole and then a 9 16 in hole angling up into the bottom cowl Front View Side View dno 6B 16 LOWER UNIT 2 Install the shift cable to the jet drive Use the exist ing mounting hardware supplied with the out board Adjust shift cable after kit is installed a Shift Cable b Bolt C Locknut d Flat Washer 3 Lubricate the shift cable Slide the cable boot onto the cable 00000054 T I rm I i o gt a Cable Boot b Lubricant 90 814676R1 DECEMBER 1996 4 Slide the shift cable through the drilled hole 5 Position the cable boot 1 2 in 12 mm out of the drilled hole 6 Fasten shift cable to the engine with J clip NE Ox a Position Cable Boot 1 2 in 12 mm Out of Drilled Hole b J Clip 7 Install bolt and 21 32 in long spacer into bottom hole on the exhaust cover Do not tighten bolt at this time a Bolt 1 3 4 in Lo
331. nly in three stages until torque of 200 Ib in 22 6 is achieved a Exhaust Cover b Divider Plate C Gaskets 4 44 POWERHEAD eo Qo 468 p o gor 50532 Torque Sequence Exhaust Cover 18 Install balance tube with fittings into cylinder block Apply pipe sealant obtain locally to fitting threads NOTE Manual start models and some early electric models have a T fitting for the fuel enrichment hose in the balance tube Later electric start models will not have this T fitting 19 Apply pipe sealant obtain locally to bleed check valve threads and install bleed hose and check valve on cylinder block NOTE The bleed check valve allows excess crank case lubricant to flow one way from the bottom of the crankcase to the top end cap bearing to provide addi tional lubrication Inspect check valve for proper op eration by applying vacuum to outlet side of check valve barbed end No restriction to flow should be felt Apply vacuum to threaded side of check valve A restriction to flow should be felt indicating check ball is seating properly If these test results are not obtained check valve must be replaced 90 814676R1 DECEMBER 1996 21 Install transfer port cover and new gasket Apply Loctite Grade A to screw threads and torque screws to 65 Ib in 7 3 N m a Transfer Port Cover b Gaskets Screws 6 Each
332. nner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs 7 Allow shock rod piston to cool Remove from shock rod 51146 Spanner Wrench Shock Rod Piston o 8 Inspect check valve for debris clean debris from check valve if found If debris cannot be cleaned from check valve replace shock piston as an as sembly 9 Clean shock and components with compressed air 5E 32 MID SECTION ax i 10 Remove inner o ring from shock rod piston 51199 a Shock Piston b O ring 11 Remove cylinder end cap assembly from shock rod 12 Inspect shock If wiper located in cap has failed to keep rod clean replace wiper 13 Place end cap on clean work surface 14 Remove rod wiper inner o ring and outer o ring 51145 a Rod Wiper b Inner O ring Outer O ring 90 814676R1 DECEMBER 1996 c Memory Piston Removal 1 Remove memory piston from cylinder using one of two methods a Using lock ring pliers Craftsman P N 4735 or suitable tool LOCK RING PLIERS A b Blowing compressed air into manual release valve hole using adaptor P N 91 822778A3 Memory piston cup may be expelled at a high velocity when air pressure is applied Failure to place cylinder as shown below could result in personal injury 51144 NOTE Point cylinder opening down and away Use a shop rag or towel to avoid damage to the memory piston a Adaptor Air Hose b Memory Pi
333. no continuity through sensor If continuity exists sensor is faulty If all of the checks are positive the Warning Module is faulty Replace Module and retest 90 814676R1 DECEMBER 1996 OIL INJECTION SYSTEM 8 7 Installing Drive Gear for Oil Injection Pump Onto Crankshaft 1 Refer to Section 4A Powerhead for proper dis assembly of components 2 Inspect gear teeth for signs of fretting or exces sive wear Check teeth and hub of gear for cracks Do not mistake plastic flow lines as cracks Gear MUST BE replaced if excessive wear fretting or cracks are observed 3 Install key in keyway of crankshaft 4 With chamfered side of gear facing 4 crankshaft throw slide gear onto crankshaft engaging key into gear against crankshaft throw 4 54864 Gear Chamfer Key 4 Crankshaft Throw e Refer to Section 4A Powerhead for proper reas sembly of powerhead components 8 8 OIL INJECTION SYSTEM gt Oil Pump Volume Flow NOTE The following specifications are determined with the outboard running off a remote fuel supply with pre mix fuel The oil pump output hose must be disconnected from the input fuel line TEE fitting and directed into a graduated container The input fuel line TEE fitting from which the oil line was removed MUST BE CAPPED OFF to prevent fuel leakage while the engine is running
334. nstallation REMOVAL 1 Remove water pump assembly as shown INSTALLATION IMPORTANT If impeller being installed has been previously used and vanes have taken a set DO NOT install the impeller with the vanes reversed from their previous set as vane breakage will occur shortly after unit is returned to service NOTE Apply a light coat of 2 4 C w Teflon to inside of pump body to ease installation of body over impel ler 1 Seatthe metal ring into the counter bore below the water pump 2 Reassemble water pump assembly as shown Rotate drive shaft CLOCKWISE while pressing water pump body down over impeller Y 2 4 C With Teflon 92 825407A12 Locknut and Flat Washer 3 Torque to 30 Ib in 3 4N m Water Tube Seal and Washer Rubber Ring Water Pump Body Assembly Impeller Key Gasket Plate Base Metal Ring Seal Exhaust Tube Place into Jet Drive Housing ES 700009 xo 6B 12 LOWER UNIT a Bearing Carrier Removal and Installation REMOVAL 1 Remove water assembly 2 Remove 4 bolts securing bearing carrier to jet drive and remove bearing carrier INSTALLATION 1 Reinstall bearing carrier as shown a Bolts 4 Apply Loctite 271 to Threads Torque to 70 Ib in 7 9 N m 90 814676R1 DECEMBER 1996 cM Bearing Carrier Disassembly 1 90 814676 1 Remove large beveled snap rin
335. nt crankshaft exists If this is the case the powerhead must be disas sembled 1 12 IMPORTANT INFORMATION Submerged Engine Fresh Water Plus Special Instructions 1 2 10 11 Recover engine as quickly as possible Remove cowling Flush exterior of outboard with fresh water to re move mud weeds etc DO NOT attempt to start engine if sand has entered powerhead as power head will be severely damaged Disassemble powerhead if necessary to clean components Remove spark plugs and get as much water as possible out of powerhead Most water can be eliminated by placing engine in a horizontal posi tion with spark plug holes down and rotating fly wheel Pour alcohol into carburetor throat alcohol will absorb water Again rotate flywheel Turn engine over and pour alcohol into spark plug openings and again rotate flywheel Turn engine over place spark plug opening down and pour engine oil into throat of carbure tors while rotating flywheel to distribute oil throughout crankcase Again turn engine over and pour approximately one teaspoon of engine oil into each spark plug opening Again rotate flywheel to distribute oil in cylinders Remove and clean carburetors and fuel pump assembly Reinstall spark plugs carburetors and fuel pump Attempt to start engine using a fresh fuel source If engine starts it should be run for at least one hour to eliminate any water in engine If e
336. ntrol Installation 7 19 Shift Cable Installation and Adjustment to ENGINE esi bg be QU UE ddp ids 7 19 Throttle Cable Installation and Adjustment to PAGING sd e aa 74 20 Connecting Remote Control Wiring Harness to Engine Wiring Harness Electric Start Models 7 21 Power Trim Wiring Connections Models So Equipped 7 22 Battery Connections 74 22 Connecting Remote Control Stop Switch Wiring to Engine Wiring Manual Start Models 7 23 90 814676R1 DECEMBER 1996 Locate Centerline Of The Boat Transom Locate and mark with pencil the vertical centerline of boat transom o 0 a Centerline of Transom NOTE Dimensions A amp B and C amp D are equal length IMPORTANT During installation of dual outboards the following is recommended A minimum of 21 in ches 533 mm centerline to centerline width is rec ommended This is required to alleviate cowling in terference during lock to lock turns if one outboard would be in the full tilt position while the other out board s are in the vertical running position Lifting Outboard Verify that the lifting ring a is threaded into the flywheel a minimum of 5 turns and that hoist has amaximum lift capacity over 500 Ibs 227 kg BE FORE lifting outboard 1 Electric Start Models Remove plastic cap from center of flywheel T
337. o small orthey may have too heavy a spring The pres sure drop across these valves can create operational problems and or powerhead damage by restricting fuel to the fuel pump and carburetor s Some symp toms of restricted lean fuel flow which could be caused by use of an anti siphon valve are Loss of fuel pump pressure Loss of power High speed surging Preignition detonation piston dome erosion Outboard cuts out or hesitates upon acceleration Outboard runs rough Outboard quits and cannot be restarted Outboard will not start uoc gt Vapor lock 3 4 FUEL SYSTEM AND CARBURETION c Since any type of anti siphon device must be located between the outboard fuel inlet and fuel tank outlet a simple method of checking if such a device or bad fuel is a problem source is to operate the outboard with a separate fuel supply which is known to be good such as a remote fuel tank If after using a separate fuel supply it is found that the anti siphon valve is the cause of the problem there are 2 solutions to the problem either 1 remove the anti siphon valve or 2 replace it with a solenoid operated fuel shutoff valve Testing Install clear fuel hose s between fuel pump and car buretor s Run engine and inspect fuel passing thru hose s for air bubbles If bubbles are found see Air Bubbles in Fuel Line below If bubbles are NOT found see Lack of Fuel Pump Pressure Troubles
338. o bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 5D 12 MID SECTION No Voltage Indicated Connect Voltmeter red lead to Point 7 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 7 and 8 90 814676R1 DECEMBER 1996 Troubleshooting Down and Up Circuits All Circuits Check in line fuse under cowl to Inoperative see if fuse is blown Remote Control NOT Equipped with Trailer Button Blown Fuse Fuse Not Blown Correct problem that caused Connect Voltmeter red lead to fuse to blow Point 3 and black lead to ground Replace fuse Battery voltage should be indi cated No Voltage Indicated Battery Voltage Indicated Check battery leads for poor Connect Voltmeter red lead to connections or open circuits Point 8 and black lead to ground Depress Up trim button and check for battery voltage Battery Voltage Indicated Check black ground wires for No Voltage Indicated poor connection or poor ground Connect red Voltmeter lead to Pump motor is faulty Refer to Point 5 and black lead to ground Motor and Electrical Tests Rep air following No Voltage Indicated Check that voltage is being supplied to control by performing the following checks DO NOT start engine Turn ignition switch to po sitio
339. o drive shaft housing and insert into seal located at bottom of exhaust plate p OMS Ze SN 54816 NOTE If arive shaft splines will not align with crank shaft splines while performing step 10 turn propel ler shaft while gear housing is being pushed toward drive shaft housing 9 Position gear housing so that the drive shaft is protruding into drive shaft housing 10 Move gear housing up toward drive shaft housing while aligning upper shift shaft splines with shift shaft coupler splines water tube with water tube seal and crankshaft splines with drive shaft splines 11 Install lock nuts and washer 4 securing gear housing to drive shaft housing 12 Torque lock nuts a to 40 Ib ft 54 N m 90 814676R1 DECEMBER 1996 Filling Gear Housing with Lubricant 1 Install new gaskets on fill and vent screws 2 With gear housing in vertical position fill gear case thru Fill hole a using Quicksilver Gear Lube until lubricant flows thru Vent hole b and no air bubbles are visible Drain approximately one fluid ounce 30cc of lu bricant from gear housing to allow for lubricant expansion 4 Install vent screw Remove lubricant tube and quickly install Fill screw le lelelelslel 54817 a Fill Screw with Gasket b Vent Screw with Gasket 90 814676R1 DECEMBER 1996 Propeller Trim Tab Install
340. oard end of Ride Guide steering cable thru grease fitting next to cable attaching nut with Quicksilver 2 4 C Marine Lubricant NOTE Ride Guide Steering cable is lubricated at the factory and requires no additional lubrication at initial installation 90 814676R1 DECEMBER 1996 Cn 2 Lubricate all steering system pivot points and exposed portion of steering cable core with Quicksilver 2 4 C Marine Lubricant Lubricate at intervals specified preceding 3 Check steering system components for wear at intervals intervals specified preceding Replace worn parts 4 Check steering system fasteners at intervals specified preceding to be sure that they are torqued to correct specifications Figures 1 2 and 3 Selecting Steering Cable and Remote Control Cables Refer to Quicksilver Accessories Guide to deter mine correct length of steering cables and remote control cables IMPORTANT Steering cable and remote control cables must be the correct length sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables Remote Control Installation IMPORTANT Install control cables to remote control and mount remote control BEFORE at taching control cables to engine Install throttle and shift cables to remote control and mount remote control as outlined in the installation instructions which accompany the remote control
341. od Dowel Pin Pivot Pin Rod Wiper O ring 671 in 1 0 Oylinder Cap O ring 1 864 in I D O ring 614 I D Trim Rod Piston Ball 5 Seat Spring 5 Spring 5 Retainer Plate Screw 3 O ring 1 600 in 1 0 2 Memory Piston Trim Rod Cylinder Screw 2 O ring 208 1 0 2 O ring 114 1 0 Spool O ring 301 in 1 0 Sleeve Spring Valve Seat Valve Spring 2 Ball Dowel Pin 2 Manifold O ring 114 in 1 0 O ring 208 I D O ring 239 I D Relief Valve E Clip Dowel Pin O ring 176 in 1 0 Bolt Drive Shaft O ring 2 364 I D Reservoir Bolt 4 Washer 4 O ring 538 I D Fill Screw Wire Harness Cap Washer Grommet Screw 4 Screw Reservoir Cap O ring 2 634 in I D Nut 2 Disk Foam Pad End Cap Washer 2 030 in Thick Thrust Washer Armature Washer 010 in Thick Housing End Frame O ring 489 I D Bolt 2 Trim Pump 90 814676R1 DECEMBER 1996 Torque Specifications 35 lb in 4 0 9 100 bb in 11 3 N m Q 70 lb in 90 lb in 25 lb in 1 in 7 9 10 2 N m 2 8 1 5 c Quicksilver Lubricant Sealant Application Points B A Loctite Grade 271 Special Lubricant 101 MID SECTION 5C 3 Power
342. oid c Turn ignition key to Start position proceed to TEST 7 TEST 3 a Reconnect black ground wire b Connect voltmeter between common engine 12 Volt Reading Defective starter motor No voltage reading proceed to TEST 4 ground and Test Point 3 solenoid c Turn ignition key to Start position TEST 4 12 Volt Reading No voltage reading proceed to TEST 5 a Connectvoltmeter between common engine ground and Test Point 4 b Turn ignition key to Start position Neutral start switch is open or yellow red wire is open between Test Points 4 and 3 No voltage reading proceed to TEST 6 TEST 5 Connect voltmeter between common engine ground and Test Point 5 12 Volt Reading Defective ignition switch No voltage reading check red wire between battery 4 positive and Test Point 6 TEST 6 Connect voltmeter between common engine ground and Test Point 6 12 Volt Reading Check fuse if equipped in red wire between test points 5 and 6 Check for open red wire between Test Points 5 and 6 No voltage reading defective starter solenoid TEST 7 a Connect voltmeter between common engine ground and Test Point 1 b Turn ignition key to Start position 12 Volt Reading Should hear solenoid click
343. on Fluid ATF Type FA or Dexron II up to threads of reservoir 50241 3 Using a 12 volt power supply connect positive lead to green wire negative lead to blue wire and drive trim rod to the down position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Re check fluid level add fluid if required and repeat cycle until fluid level remains at lower portion of threads 4 Install fill plug 90 814676R1 DECEMBER 1996 Power Trim Unit Installation 1 Apply Special Lubricant 101 92 13872A1 to lower pivot pin hole and pivot pin surface Start lower pivot pin into pivot pin bore and posi tion lower dowel pin RETAINED in its respective hole 51148 Lower Pivot Pin Lower Dowel Pin Position trim cylinder assembly BOTTOM FIRST between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket a Trim Cylinder Assembly MID SECTION 5B 37 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 Lower Pivot Pin 5 Using a suitable punch drive lower dowel pin into its respective bore until seated a Lower Dowel Pin 6 Apply 2 4 C Marine Lubricant 92 90018A12 to surface of upper pivot pin pivot pin bore and trim ram bore a Pivot Pin b Pivot Pin Bore Trim R
344. on Troubleshooting Engines With Black Stator STEP 3 Stator Low Speed and High Speed Test Stator Low Speed Test Stator High Speed Test 3 imb S555 26 s 50 Ai o EIE 1 Use Multimeter DVA Tester 91 99750 2 Crank engine and observe meter reading IGNITION VOLTAGE 9 AMP STATOR Selector Reading At Reading At Blue Sw Stator Low Speed 400 VDC 210 310 190 310 Red Sw Stator High Speed 400 VDC 25 90 140 310 IGNITION VOLTAGE 16 AMP STATOR 398 9710 amp 398 9710A42 Selector Voltage Voltage Voltage Blue Sw Stator Low Speed 400 VDC Box Term Ground 160 200 315 385 270 330 Red Sw Stator High Speed 400 VDC 8 10 27 33 165 205 TEST RESULTS e f voltage output is low to either the stator low speed or stator high speed the stator or switch box is defective Go to stator test and test stator If stator tests OK replace switch box and repeat step e f voltage output is good to either the stator low speed or stator high speed replace the switch box and repeat step 90 814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION 2A 5 PAN Ignition Troubleshooting Engines With Red Stator Troubleshooting Sequence Chart Engine with Red Stator Start the ignition troublesho
345. on insert locknut as shown Torque spe cial bolt to 20 Ib ft 27 N m then torque locknut to 20 Ib ft 27 N m a Flat Washer 2 b Nylon Insert Locknut Torque Until It Seats DO NOT Ex ceed 120 Ib in 14 N m of Torque Then Back Nut Off 1 4 Turn c Special Washer Head Bolt P N 10 14000 Torque to 20 Ib ft 27 1 N m d Nylon Insert Locknut Torque to 20 Ib ft 27 N m e Steering Link Rod After installation is complete and before operat ing outboard check that boat will turn to right when steering wheel is turned right and that boat will turn left when steering wheel is turned left Check steering thru full range left and right at all tilt angles to assure interference free movement 90 814676R1 DECEMBER 1996 Maintenance Instructions Maintenance inspection is the owner s responsibility and must be performed at intervals specified Normal Service Every 50 hours of operation or 60 days whichever comes first Severe Service Every 25 hours of operation or 30 days whichever comes first Operation in salt water is considered Severe Service 1 Carefully check steering system components for wear Replace worn parts 2 Check steering system fasteners to be sure that they are torqued to correct specifications NOTE Ride Guide Steering cable is lubricated at the factory and requires no additional lubrication at initial installation Core of steering cable transom
346. onnect positive lead to green wire negative lead to blue wire and drive trim rod to the down position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Re check fluid level add fluid if required and repeat cycle until fluid level remains at lower portion of threads 90 814676R1 DECEMBER 1996 fi Power Trim Unit Installation 1 Apply Special Lubricant 101 92 13872A1 to lower pivot pin hole and pivot pin surface 2 Start lower pivot pin into pivot pin bore and posi tion lower dowel pin RETAINED in its respective hole 51148 Lower Pivot Pin Lower Dowel Pin 3 Position trim cylinder assembly BOTTOM FIRST between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket oo a Trim Cylinder Assembly 90 814676R1 DECEMBER 1996 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 Lower Pivot Pin Using a suitable punch drive lower dowel pin into its hole until seated 51148 a Lower Dowel Pin MID SECTION 5C 37 6 Apply Special Lubricant 101 92 13872 1 to surface of upper pivot pin pivot pin bore and trim ram bore 08 EL 51148 Pivot Pin Pivot Pin Bore Trim Ram Bore 7 Using a suitable mallet drive upper pivot pin into swivel bracket and
347. ose b Memory Piston Exit c Shop Rag 90 814676R1 DECEMBER 1996 2 1 2 Remove O ring from memory piston 51144 a O Ring b Memory Piston Valve Block Disassembly 1 Remove check retainer plug and components 2 Remove hydraulic oil transfer valve plugs and components 8 8 Transfer Valve Plug Assembly 2 b Check Retainer Plug or Screw Assembly 51142 90 814676R1 DECEMBER 1996 3 Remove surge valve assembly a Spool b Spring c O ring d Screw Plug 4 Remove screw and remove cam assembly a Spacer Retainer Clip b Retainer Clip Screw d Shaft Seal Cam MID SECTION 5G 23 c REASSEMBLY O RING AND SEAL PLACEMENT NOTE Lubricate all O rings using Quicksilver Power Trim and Steering Fluid If not available use automotive ATF automatic transmission fluid NOTE It is recommended that all O rings be replaced when servicing tilt system 5G 24 MID SECTION 90 814676R1 DECEMBER 1996 Actual O ring Sizes full E 4 14 Cutaway View of O Ring O RINGS SHOWN ARE ACTUAL SIZE 90 814676R1 DECEMBER 1996 MID SECTION 5G 25 O ring Description and Sizes Description Ong ID Co peu 0000 3 Ocm mer 057 704 2430 mm 0159 G9 _ 3 Oc 34mm 2041 S030 mm 071 178 m
348. osition or returns part way with jerky motion Outboard thumps when shifted Refer to Hydraulic System Refer to Electrical System Troubleshooting Troubleshooting Outboard trails out when backing off throttle at high speed Outboard will not hold a trimmed position or will not remain tilted for any extended period Outboard will not hold trim position when in reverse 90 814676R1 DECEMBER 1996 MID SECTION 5C 11 Hydraulic System Troubleshooting Support outboard with tilt lock lever when servicing power trim system IMPORTANT After debris or failed components have been found during troubleshooting proce dure it is recommended that unit be disas sembled completely and ALL O rings be re placed Check ball valve components and castings must be cleaned using engine cleaner and compressed air or replaced prior to reas sembly IMPORTANT Power trim system is pressurized Outboard must be in the full UP position trim rod fully extended prior to fill drain plug or man ual release valve removal Refer to instructions following if disassembly is re quired when servicing Follow preliminary checks before proceeding to trou bleshooting flow diagrams following Preliminary Checks IMPORTANT Operate Power Trim system after each check to see if problem has been corrected If problem has not been corrected proceed to next check 1 Check that manual release valve is tightened to full ri
349. oting by first performing Step 1 then continue the series of steps to locate the problem Refer to the troubleshooting steps on the following pages Low or No Voltage at all coils Step 2 High Voltage at all coils E Step 1 Primary Voltage At The Test Trigger Ignition Coils Test Pawar Ne Page 2A 10 Low or No Voltage at one coil Test for Spark Good Voltage at all coils Page 2A 11 RED Stator Test Test Selector RED DVA BLACK DVA Voltage Voltage Voltage Switch Posi Lead Lead 300 RPM 1000 RPM 4000 RPM tion Coil Primary 400 VDC Coil Coil 130 Volts 195 to 275 195 to 275 Terminal Terminal Minimum Stop Circuit 400 VDC Black Yellow Ground 190 Volts 275 to 320 260 to 320 Sw Box Minimum Terminal Blue Sw Box 400 VDC Blue Sw Box Ground 190 Volts 275 to 320 260 to 320 Terminal Terminal Minimum Blue White Sw 400 VDC Blue White Sw Ground 190 Volts 275 to 320 260 to 320 Box Terminal Box Terminal Minimum 2 6 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Ignition Troubleshooting Engines With Red Stator STEP 1 Primary Voltage At The Ignition Coils Test Connect Test Lead To Coil Terminal Connect Test Lead To Coil Terminal 1 Use Multimeter DVA Tester 91 99750 Set Switch position to 400 DVA 2 Crank engine and observe meter reading Voltage at 300 RPM Voltage at 1000 4000 cranking
350. ount Rubber Upper 2 Seal Upper Mount 2 Washer 2 Washer Rubber 2 Washer 2 Nut 2 14 Cover Upper Mount 2 15 Screw 4 16 Washer 4 17 Tube Exhaust 18 Tube Water Inlet 19 Cover Lower Mount Clamp 20 Screw 2 21 Clamp Lower Mount 2 22 Screw 4 23 Spring Tension 4 24 Nut 2 25 Screw 2 26 Ground Wire 27 Washer 2 28 Washer Rubber 2 29 Mount Rubber Lower 2 30 Washer 2 31 Nut 2 32 Exhaust Adaptor P late 33 Seal 34 Bushing 35 Washer Nylon 36 Seal Rubber 37 Gasket 38 Housing 39 Screw 2 40 Gasket 41 Gasket 42 Shift Shaft Lever 43 Bushing 2 44 Shift Link 45 Wave Washer 2 46 Nut 2 47 Washer 2 48 Slider 49 Retainer 50 Stud 51 Retaining Ring 52 Retainer 53 Screw 2 Torque Specifications 80 lb in 9 0 N m 150 lb in 17 N m 40 Ib ft 54 2 N m 90 814676R1 DECEMBER 1996 Quicksilver Lubricants and Service Aids A 2 4 C Marine Lubricant S ee Quicksilver Accessories Guide for part number MID SECTION 5A 3 Disassembly Reassembly 1 Remove shock system assembly refer to Sec ion 5D f ls Tilt Lock Lever Transom Bracket 2 Remove power trim assembly refer to Section 5 mE B or 5C from power trim models 1 Apply Quicksilver 2 4 Marine Lubricant to tilt lock lever shank
351. outed down starboard side of boat to port outboard Steering link rod MUST BE secured between out board steering arm bracket and steering cable end using special washer head bolt P N 10 14000 and two nylon insert locknuts P N 11 34863 as shown Both special washer head bolt and nylon insert locknuts MUST BE tight ened as specified Lubricate hole in end of steering cable with Quicksil ver 2 4 C Marine Lubricant Assemble steering link rod to steering cable end using 2 flat washers and nylon insert locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 14 N m of torque then back nut off 1 4 turn Lubricate ball joint in steering link rod with SAE 30W Motor Oil Secure link rod to outboard steering arm inner hole closest to outboard using special wash er head bolt P N 10 14000 provided and nylon in sert locknut as shown Torque special bolt to 20 Ib ft 27 N m 50056 a Flat Washer 2 b Nylon Insert Locknut Torque Until It Seats DO Ex ceed 120 Ib in 14 of Torque Then Back Nut Off 1 4 Turn Special Washer Head Bolt P N 10 14000 Torque to 20 Ib ft 27 1 N m d Nylon Insert Locknut Torque to 20 Ib ft 27 N m e Steering Link Rod 90 814676R1 DECEMBER 1996 After installation is complete and before operat ing outboard check that boat will turn to right when steering wheel is turned right and that boat will turn left when steering wheel is tur
352. p Coupling Screw Key Electric Start Models 33 34 35 36 Enrichener Valve Clamp Tee Fitting Check Valve Manual Start Models 37 90 814676R1 Primer Bulb To Y To Fuel Electric Connector Black Fuel Pump Body Torque Specifications 40 bb in 4 5 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 3 Fuel Pump General Information FUEL PUMP DESCRIPTION OPERATION The fuel pump is a crankcase pressure operated diaphragm type pump Crankcase pulsating pres sure created by the up and down movement of pis ton is transferred to fuel pump by way of a passage hole between crankcase and fuel pump When piston is in an upward motion a vacuum is created in the crankcase thus pulling in a fuel air mixture from carburetor into crankcase This vacu um also pulls in on the fuel pump diaphragm thus the inlet check valve in fuel pump is opened and fuel from fuel tank is drawn into fuel pump Downward motion of the piston forces the fuel air mixture out of the crankcase into the cylinder This motion also forces out on the fuel pump diaphragm which in turn closes the inlet check valve to keep fuel from returning to fuel tank and opens the outlet check valve thus forcing fuel to the carburetors CHECKING FOR RESTRICTED FUEL FLOW CAUSED BY ANTI SIPHON VALVES While anti siphon valves may be helpful from a safety stand point they clog with debris they may be to
353. panel is equipped with a switch that is used for trimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running Adjustments Trimming Characteristics NOTE Because varying hull designs react differently in various degrees of rough water it is recommended to experiment with trim positions to determine wheth er trimming up or down will improve the ride in rough water When trimming your outboard from a mid trim posi tion trim tab in neutral straight fore and aft posi tion you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at high speed reduce the power gradually and trim the motor In slightly before resuming high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instabili ty e Will lift bow of boat generally increasing top speed e Transfers steering torque harder to left on instal lations below 23 in transom height e Increases clearance over submerged objects e n excess can cause porpoising and or ventila tion e In excess can cause insufficient water supply to water pump resulting in serious water pump and or powe
354. particularly with a heavy load e Usually improves ride in choppy water e n excess can cause boat to veer to the left or right bow steer e Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt pin one hole closer to transom Operating Down circuit will actuate the down relay located under engine cowl and close the electric motor circuit motor will run in opposite direction of the Up circuit The electric motor will drive the pump thus forcing automatic transmission fluid through internal passageways into the down side of the trim cylinder The trim rod will move the engine downward to the desired angle 90 814676R1 DECEMBER 1996 c Trailering Outboard Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running While operating up circuit the cylinder rod will con tinue to tilt the outboard to a full position for trail ering 90 814676R1 DECEMBER 1996 Tilting Outboard Up and Down Manually Before loosening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is loos ened With power trim installed the outboard can be raised or lowered manually by opening the m
355. place bent shaft Forward Reverse an Pinion Gears Replace gear if gear teeth a or clutch teeth b are chipped or worn 54784 90 814676R1 DECEMBER 1996 c Sliding Clutch Inspect sliding clutch Check reverse gear slide clutch jaws if jaws are rounded replace as nec essary Rounded clutch jaws can be caused by the following Improper shift cable adjustment Engine idle speed RPM too high when shifting Shifting outboard from neutral to reverse too slowly Cam Follower 1 90 814676R1 Replace cam follower if end of follower shows signs of wear 54786 DECEMBER 1996 Water Pump Components 1 Inspect impeller Replace impeller if any of the following conditions exist Impeller blade s are cracked torn or worn Impeller is glazed or melted caused by operation without sufficient water supply Rubber portion of impeller is not bonded to impel ler hub Drive Shaft 1 Inspect drive shaft Replace drive shaft if any of the following exists Bent drive shaft Twisted splines Damaged drive shaft oil seal needle bearing sur faces J 54788 a Splines b Needle Bearing Surface c Oil Seal Surface LOWER UNIT 6 15 Shift Shaft 1 Inspect shift shaft and cam Replace compo nents if any of the following exists Corroded or worn shift shaft splines both ends e Grooves in shift shaft seal surface e Worn shift cam 54789
356. plug as trapped air will prevent housing from being filled Fill gear housing only when outboard is in operating posi tion 7 With outboard in operating position insert lubri cant tube into fill hole 8 Fill gear housing with lubricant until excess starts to flow from VENT hole 9 Atthis point drain approximately one fluid ounce 30ml from gear housing to permit expansion of lubricant 10 Install VENT plug and washer 11 Remove lubricant tube and install cleaned mag netic fill plug with washer Salt Water Corrosion Gear Housing Bearing Carrier and Cover Nut Salt water corrosion buildup can be sufficient to split a gear housing and destroy an entire lower unit To protect against such damage therefore it is recom mended that the gear housing bearing carrier and gear housing cover nut be lubricated on a regular ba sis as follows Service first at the 20 hour inspection then on an annual basis Remove the cover nut and entire bearing carrier to adequately clean corrosive de posits and dried up lubricant from both ends of the bearing carrier as well as the gear housing internal threads and cover nut external threads Apply a lib eral amount of Quicksilver Special Lubricant 101 or 2 4 C Marine Lubricant to the 2 ends of the bear ing carrier and to the gear housing and cover nut threads then reassemble and retorque Refer to gear housing disassembly and reassembly Sec tion 5 90 814676R1 DECEMBER 1996
357. powerhead onto driveshaft housing IMPORTANT The forward starboard and port powerhead attaching nuts MUST BE started onto their respective studs BEFORE powerhead is completely lowered onto driveshaft housing 54737 a Thread Attaching Nut Onto Forward Most Stud One Each Side First Before Lowering Powerhead Assembly Com pletely Onto Driveshaft Housing 6 Install remaining powerhead attaching nuts Tighten nuts equally in three progressive stages until a torque of 150 Ib in 16 9 N m is obtained 54672 a Attaching Nuts 4 Each Side Torque to 150 Ib in 16 9 N m 90 814676R1 DECEMBER 1996 7 Secure lower trim cover to bottom cowl with four bolts and self locking nuts 2 each side 54671 a Bolts 2 Each Side b Trim Cover 8 On ELECTRIC START MODELS reinstall oil tank referring to Section 8 9 Reinstall rewind starter or flywheel cover where applicable referring to Section 2A 10 Reinstall spark plugs Torque spark plugs to 20 Ib ft 27 1 N m 11 On ELECTRIC START MODELS reconnect re mote control harness to engine harness 12 Refer to Section 2C for TIMING SYNCHRONIZ ING ADJUSTING procedure 13 Attach throttle and shift cables 14 Attach remote fuel hose to engine NOTE Gear Case lubricant level should be checked prior to operating outboard Refer to Section 5A for correct inspection and filling procedures If new bear ings a
358. r and pump reservoir as sembly together a Trim Cylinder Assembly b Reservoir Manifold Assembly 90 814676R1 DECEMBER 1996 Q 3 Install the two 2 long screws and torque to 100 Ib in 11 N m 51146 a Screws 2 Torque to 100 Ib in 11 N m 90 814676R1 DECEMBER 1996 Oil Pump Installation 1 Install spring ball lubricated O ring and plastic seat to manifold 2 Check to see that O rings are placed on bottom of pump 3 Install filter and filter seal under pump Install pump onto manifold Torque screws to 70 10 in 7 7 a Screws 3 Torque to 70 Ib in 7 7 b Suction Seat Assembly MID SECTION 5E 41 Pressure Operated Assembly Installation IMPORTANT Inspect poppet assembly for debris in the area shown If debris is found on poppet re place poppet a Debris Under Valve Tip b Rubber Seat 1 Lubricate o rings 2 Install spool seat with O ring check valve pop pet spring and plug with O ring into pump Re peat for other side Torque plugs to 120 10 in 13 5 N m Plugs 2 Torque to 120 Ib in 13 5 N m Springs 2 Check Valve Poppet 2 Seats 2 Spool 5 42 MID SECTION Reservoir Motor Installation 3 Install coupler into top of pump Make sure reser voir seal is in the reservoir groove and place res ervoir onto pump manifold assembly Install ground strap under screw shown Torque screws to
359. r most applications however because of dif ferent boat hulls designs the setting should be re checked by test running the boat Refer to Water Testing e Installing the outboard too high on the transom will allow the water intake to suck in air and cause ca vitation Cavitation will cause the engine to over speed in spurts and reduce thrust This condition should be avoided by proper height setting e Installing the outboard too low on the transom will allow excessive drag 90 814676R1 DECEMBER 1996 SETTING OUTBOARD MOUNTING HEIGHT ON BOATS WITH V BOTTOM HULLS 1 Measure the width of the leading edge on the wa ter intake housing Make a horizontal line a on the transom up from the V bottom the same length as the width of the water intake housing b MN 2 Place center the outboard on the boat transom 50 the transom brackets are resting on top of the transom Temporarily fasten the outboard to the transom using two C clamps 3 Position the outboard in a vertical position Line up a straight edge c along the bottom of the boat with the horizontal line made in Step 1 and measure the distance between the horizontal line and top front edge of the water intake housing d 5 Raise The outboard up on the transom the dis tance measured in Step 4 Use a straight edge and recheck the mounting height The top edge of the water intake housing should be lined up with the horizontal line made in Step 1
360. r nut bore Place the plastic sleeve inside the impeller and install impeller shear key shims nut retainer and impeller nut Turn the nut tight on the shaft to remove any play between the impeller and shaft If the tabs on the retainer do not line up with the flats on the nut remove the nut and turn the retain er over and re tighten the nut a Tabs 4 Reinstall the water intake housing with six bolts Check clearance around the impeller to make sure the water intake housing is centered and not rubbing against the liner Torque mounting bolts to 96 Ib in 10 8 N m amp amp d amp f Plastic Sleeve Impeller Shear Key Shims Nut Retainer Impeller Nut Temporarily reinstall the water intake housing order to check for impeller clearance The clear ance between the impeller and liner should be 0 030 in 0 8 mm Shim washers can be trans ferred to either side of the impeller to raise or low er the impeller to the correct clearance setting The water intake housing can be shifted sideways a small amount in order to center the liner NOTE If the outboard is used in salt water apply Fe Quicksilver Anti Corrosion Grease around the entire mounting flange on the water intake housing and also to the threads on the six mounting bolts 55535 Wasi N 03 in 8mm 90 814676R1 DECEMBER 1996 LOWER UNIT 6B 9 Steerin
361. r to the tor Jet Chart following and rejet carburetor for ele vation outboard will be operated at Carburetor Jet Orifice Sizes WMA7B Jet to 2500 Se 5000 T 7500 T and arum Type Main Se 1457 ae 1655 EUR 1653 Faser 1651 4 Cyl Vent 1399 7335 1399 6249 1395 8423 1395 5733 8 32 Thread 10 32 Thread Carburetor Jet Orifice Sizes WMA9 Jet Type Main Top Main Bot 1395 823621 1395 823622 Vent 1399 7335 10 32 Thread 3 16 FUEL SYSTEM AND CARBURETION Standard Jet up to 2500 2500 5000 5000 7500 7500 and Up Size PartNo Size PartNo Size PartNo Size 1395 823621 3 046 1395 823621 2 1395 823622 3 046 1395 823622 2 1399 6249 1395 823621 1 1395 823622 1 1395 8423 1395 5733 90 814676R1 DECEMBER 1996 Enrichment System Electric Start Models The enrichener system electric start models pro vides the engine with a rich fuel charge supplied from the float bowl of the top carburetor for starting ease of a cold engine Enrichener Hose Routed to Carburetor Flanges 50571 Description The enrichener system consists of an electrically ac tuated valve With the key in the RUN position and pushed in and held in the valve is opened allowing gravity fed fuel to be delivered to the engine thru a fit ting on the bottom carburetor flange With the k
362. rankcase to drive shaft housing 1 5 8 DOWEL PIN crankcase to cylinder block STUD 4 STUD 2 1 8 STUD 2 1 2 SCREW crankcase to cylinder block 1 1 2 SCREW crankcase to cylinder block 1 3 8 SCREW crankcase to cylinder block 2 7 8 WASHER crankcase screw SCREW center main bearing locking 1 SCREW 3 4 DESIGN II LOCKWASHER w LOCKWASHER SCREW 5 8 DESIGN TAB WASHER w TAB WASHER TUBE balance main bearing ELBOW balance tube to cylinder block CONNECTOR bleed hose UPPER HOSE cylinder bleed 11 CHECK VALVE bleed hose LOWER PRIMER TEE OLD DESIGN COVER O RING NON OIL SCREW WASHER TEMPERATURE SENDER POWERBOAT CABLE ASSEMBLY PO PO POY POY AINI AIN 3 2 N CO DO O O N 90 814676R1 DECEMBER 1996 POWERHEAD 4 5 90 814676R1 DECEMBER 1996 NS A End Caps and Exhaust Cover DESIGN 111 DESIGN II DESIGN A 4 6 POWERHEAD End Caps and Exhaust Cover TORQUE DESCRIPTION Ib in Ib ft TEMPERATURE SWITCH ELECTRIC END CAP ASSEMBLY upper OIL SEAL upper end cap O RING upper end cap BALL BEARING upper end cap SHIM upper end cap 005 10 SCREW upper end cap 3 4 COVER ASSEMBLY cylinder block PIPE PLUG cylinder
363. rating of 350 amperes is recommended 2 House battery in a battery box and secure in a favorable position in boat 3 Connect battery cables to battery by connecting BLACK lead to negative terminal and con necting RED lead to positive terminal on bat Y tery H 54645 7B 10 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 90 814676R1 DECEMBER 1996 Co Pilot Installation Instructions 1 Thread friction device a onto starboard end of tilt tube until securely tightened and wind nut will be positioned toward front of outboard 2 Loosen wing nut on friction device and insert pilot rod c into friction device and tilt tube 3 Lubricate each end of link rod with Quicksilver 2 4 C Marine Lubricant 4 Install link rod d longer end into hole in steer ing handle bracket and other end of link rod into hole in pivot rod as shown 5 Secure link rod to steering handle spacer bracket with spacer flat washer and locknut Torque lock nut to 120 Ib in 13 6 N m 6 Secure link rod to pilot rod with flat washer and locknut Tighten locknut until it seats DO NOT exceed 120 Ib in 13 6 N m then back off 1 4 turn 7 Adjust wing nut on friction device to provide de sired steering control IMPORTANT Tighten wing nut b to increase friction loosen to decrease friction If the wing nut b is overtightened it ma
364. rd Reverse an Pinion Gears Sliding Clutch Cam Follower Water Pump Components Drive Shaft Shift Shaft Gear Housing Reassembly 6A 16 Drive Shaft Needle Bearing Installation 16 Shift Shaft Bushing Reassembly and Installation 6A 16 Lubrication Sleeve Installation 6A 17 Forward Gear and Bearing Heassembly 6A 17 Bearing Carrier Reassembly 6A 18 Forward Gear Race Installation 6A 19 Drive Shaft Reassembly and Installation 6A 19 Checking Pinion Gear Depth 6A 20 Propeller Shaft Reassembly and Installation 6A 20 Bearing Carrier Installation 6A 21 Checking Forward Gear Backlash 6A 23 Water Pump Reassembly and Installation 6A 23 Gear Housing Installation 6A 25 Filling Gear Housing with Lubricant 6A 27 Propeller Trim Tab Installation 6A 27 90 814676R1 DECEMBER 1996 p i Special Tools Description Cover Nut Tool Slide Hammer Puller Jaws Puller Universal Puller Plate Mandrel Shift Shaft Bushing Tool Shimming Tool Dial Indicator Gauge Dial Indicator Adaptor Backlash Indicator Rod Puller Bolt Mandrel Mandrel Mandrel
365. rew 3 Torque to 35 Ib in 3 9 N m b Plate Spring 5 d Seat 5 e Ball 5 MID SECTION 5G 29 Shock Rod Installation and Fluid Fill ing Procedure NOTE There are two ways for the filling procedure The first is the easiest and less time consuming Filling Procedure Option One 1 Place trim cylinder in soft jawed vice 2 With manifold cam lever closed Up Position fill cylinder and manifold to top with Quicksilver Power trim and steering fluid or ATF automatic transmission fluid Let bubbles disperse 3 Install lubricated O ring to memory piston Using lock ring pliers Craftsman P N 4735 or Snap on P N SRP4 set memory piston in top of cylinder then open cam lever Down Position and push memory piston down just below cylin der treads Close cam lever Up Position 51144 5 Fill top of cylinder again with fluid to top and install shock rod assembly on top memory piston Open cam lever Down Position and push shock rod assembly down to 1 8 below cylinder threads Close cam lever Up Position 5G 30 MID SECTION Cn Fill top of shock rod assembly with fluid to top of cylinder Open cam lever Down Position and screw cylinder cap down Tighten end cap securely using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs If a torquing type spanner tool is used to tighten end cap then torque the end cap to 45 Ib ft 61 0 Close cam lever up Position 51145
366. rhead overheating damage 5E 4 MID SECTION Excessive engine trim angle will result in insuffi cient water supply to water pump causing water pump and or powerhead overheating damage Make sure that water level is above gear housing water intake holes whenever engine is running Operating Up circuit will actuate the up relay lo cated under engine cowl and close the electric motor circuit The electric motor will drive the pump thus forcing automatic transmission fluid through internal passageways into the up side of the trim cylinder The trim cylinder trim rod will position the engine at the desired trim angle within the 20 maximum trim range The power trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum trim angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine RPM increases above 2000 RPM the thrust created by the propeller if deep enough in the water will cause the trim system to automatically lower the engine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering condi tions Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle tilt pin relocation e Will help planing off
367. rhead stand 91 25821A1 or work bench 26817 a Recoil Starter 12 Remove four bolts securing trim cover to bottom cowl and remove cover 54671 a Bolts 2 Each Side b Trim Cover a Lifting Eye 91 75132 90 814676R1 DECEMBER 1996 POWERHEAD 4 15 Powerhead Disassembly 1 Remove the following components assemblies referring to the listed service manual sections Component Assembly Section Rewind Starter Hyves Ignition Components Starter Motor Carburetors Fuel Pump and Fuel 3A Enrichment Valve 2 Remove two allen screws securing oil pump to crankcase cover Remove oil pump and driven gear NOTE If driven gear remains in crankcase cover it can be removed when crankcase cover is removed from cylinder block a Allen Screws b Oil Pump Driven Gear Hidden 4 16 POWERHEAD A 3 Remove three bolts attaching throttle actuator assembly to crankcase cover a Bolts b Throttle Actuator Assembly 4 Remove bolt securing throttle spark arm to ex haust manifold cover and remove arm assembly a Bolt b Throttle Spark Arm 90 814676R1 DECEMBER 1996 5 Remove bolts securing upper and lower end
368. rim Unit Installation Manual release valve must be in full closed posi 1 Apply Special Lubricant 101 92 13872A1 to tion during power trim purging and operation lower pivot pin bore and pivot pin surface 1 Secure power trim unit in soft jawed vise 2 Start lower pivot pin into pivot pin bore and posi tion lower cross pin RETAINED in its respective 2 Remove fill cap a Add Quicksilver Power Trim and Steering Fluid 92 90100A12 or Automatic Transmission Fluid ATF Type FA or Dexron II up to threads of reservoir Install cap a hole ya 2 D 7 c 51148 Lower Pivot Pin Lower Dowel Pin o mv 3 Position trim cylinder assembly BOTTOM FIRST between clamp brackets and route trim pump electrical harness through access hole in starboard clamp bracket 3 Using a 12 volt power supply connect positive lead to green wire negative lead to blue wire and drive trim rod to the down position Connect posi tive lead to blue wire and negative lead to green wire and drive trim rod to the up position Re check fluid level add fluid as required and repeat cycle until fluid level remains at lower portion of threads a Trim Cylinder Assembly 5D 26 MID SECTION 90 814676R1 DECEMBER 1996 x 4 Using a suitable punch drive lower pivot pin into clamp bracket and trim cylinder assembly until pivot pin is flush with outside surface 51147 a Lower Cross Pin
369. ring and cylinder bore Cylinder bore appears Cylinder bore appears rough and or debris smooth with no debris found in cylinder Replace memory pis ton and shock piston Trim leaks down O rings Trim system does not leak down Test ing complete Replace trim system 5E 24 MID SECTION 90 814676R1 DECEMBER 1996 p i Troubleshooting the Power Trim Electrical System Trim Switch Trim Switch Remote Control Panel Mounted Mounted Fuse e BLU WHT or PUR gt gt GRN WHT or GRN gt gt RED eee T Fuse Holder Battery Solenoid GRN WHT BLU WHT lt LT GRN WH LT GRN WHT LT BLU WH LT BLU WHT Up Relay Cowl Switch Trim Pump Motor 90 814676R1 DECEMBER 1996 MID SECTION 5E 25 Troubleshooting the Power Electrical System Refer to wiring diagram on preceding page for location of wire connections Trim Switch UP is inopera tive but the Cowl Switch UP does operate Cowl Switch UP is inopera tive but the Trim Switch UP does operate Trim Switch UP and Cowl Switch UP are both inopera tive Trim Switch DOWN is erative but the Cowl Switch DOWN does operate Cowl Switch DOWN is inop erative but the Trim Switch DOWN does operate Trim Switch DOWN and Cowl Switch DOWN are both inoperative Trim Switch UP and DOWN are both inoperative but
370. rings for rust or signs of bearing failure Replace bearings as necessary A CAUTION DO NOT intermix new and used needle bearings If replacement of some bearings is required re place all bearings at that location 3 Inspect crankshaft end and piston pin end bear ing surfaces of connecting rod for the following a Rust Rust formation on bearing surfaces causes uneven pitting of surface s 51853 a Pitting 4 28 POWERHEAD b Water Marks When bearing surfaces are subjected to water contamination a bearing surface etching occurs This etching re sembles the size of the bearing 51853 Connecting Rod with Water Marks c Spalling Spalling is the loss of bearing sur face it resembles flaking or chipping Spal ling will be most evident on the thrust portion of the connecting rod in line with the I beam The general deterioration of the bearing sur face could be caused by or accelerated by improper lubrication 51853 a Spalling 90 814676R1 DECEMBER 1996 c d Chatter Marks Chatter marks are the result of a combination of low speed low load cold water temperature operation that is aggra vated by inadequate lubrication and or im proper fuel Under these conditions the crankshaft journal is hammered by the con necting rod As ignition occurs in the cylinder the piston pushes the connecting rod with tre mendous force and this force is transferred to the connecting rod jou
371. rk plug high tension leads to spark plugs 90 814676R1 DECEMBER 1996 THROTTLE SECONDARY PICK UP ADJUSTMENT OUTBOARD NOT RUNNING 1 With engine not running advance outboard throttle lever to hold maximum spark advance screw against stop Adjust secondary throttle pick up screw so that end of screw just touches secondary lever of carburetor cluster Tighten lock nut a Secondary Throttle Pick Up Screw b Lock Nut a Secondary Throttle Pick Up Screw b Carburetor Cluster Secondary Cluster ELECTRICAL AND IGNITION 26 3 FULL THROTTLE STOP SCREW ADJUSTMENT OUTBOARD NOT RUNNING 1 Advance throttle lever to hold full throttle stop screw against stop 4 ath JE LE peer a Full Throttle Stop Screw b Stop 54665 2C 4 ELECTRICAL AND IGNITION 2 Adjust full throttle stop screw to allow full carbure tor shutter opening at wide open throttle Throttle shutters MUST NOT act as a throttle stop 010 015 0 254mm 0 381mm free play should exist between secondary pick up screw and car buretor cluster secondary lever If sufficient free play does not exist full throttle stop screw MUST BE adjusted a Secondary Pick Up Screw b Carburetor Cluster Secondary Lever c 010 in 015 in 0 254mm 0 381mm Clearance 90 814676R1 DECEMBER 1996 c Carburetor Adjustments IDLE MI
372. rnal Since there is little or no load on the crankshaft it bounces away from the connecting rod The crank shaft then remains immobile for a split se cond until the piston travel causes the con necting rod to catch up to the waiting crankshaft journal then hammers it The rep etition of this action causes a rough bearing surface s that resembles a tiny washboard In some instances the connecting rod crank pin bore becomes highly polished During op eration the engine will emit a whirr and or chirp sound when it is accelerated rapidly from idle speed to approximately 1500 RPM then quickly returned to idle If the preceding conditions are found replace both the crank shaft and connecting rod 51853 a Chatter Marks between Arrows 90 814676 1 DECEMBER 1996 e Uneven Wear Uneven wear could be caused by a bent connecting rod or improper shimming of crankshaft end play failure to maintain approximately the same amount of shim s under end cap thereby causing the crankshaft journal not centered over the cylinder bore 51853 a Uneven Wear between Arrows f Overheating Overheating is visible as a blu ish bearing surface color caused by inade quate lubrication or excessive RPM POWERHEAD 4 29 Cleaning Connecting Rods 1 If necessary clean connecting rod bearing sur faces as follows a Install connecting rod cap and bolts using 1 4 12 point socket Be sure that cap is
373. ry cables from battery and verify ignition key is in the OFF position When servicing manual start engines verify lanyard switch is in the OFF position Stator Assembly Removal 1 Remove top cowl 2 Remove 3 bolts securing rewind starter or fly wheel cover and remove rewind or cover which ever is applicable 3 Remove flywheel as outlined in FLYWHEEL RE MOVAL AND INSTALLATION preceding ELECTRICAL AND IGNITION 24 15 c 4 Remove 4 screws which secure stator to upper 5 Remove 6 bolts securing electrical box access cap cover and remove cover NOs f Hee AL N a 54645 a Screws a Bolts b Stator b Access Cover 6 Disconnect stator wiring from their respective ter minals and remove stator assembly from out board 2 16 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 Black Stator Installation 1 Apply Loctite Grade A 92 32609 1 to threads of 4 stator attaching screws 2 Install stator on upper end cap and torque attach ing screws to 35 Ib in 3 9 N m 3 Route stator wiring into electrical component box a Warning Module b Stator Wiring to Switch Box a Stator c Stator Wiring to Rectifier b Wiring 4 Recon
374. s and may form an ex plosive atmosphere around battery if ventilation is poor This explosive gas may remain in or around battery for several hours after it has been charged Sparks or flames can ignite this gas and cause an in ternal explosion which may shatter the battery The following precautions should be observed to pre vent an explosion 1 DO NOT smoke near batteries being charged or which have been charged very recently 2 DONOT break live circuits at terminals of batter ies because a spark usually occurs at the point where a live circuit is broken Always be careful when connecting or disconnecting cable clamps on chargers Poor connections are a common cause of electrical arcs which cause explosions 3 DO NOT reverse polarity of battery terminals to cable connections 4 If battery is still connected to outboard DO NOT operate any outboard or boat electrical systems that are powered by the battery while charging the battery CAUTION If battery acid comes into contact with skin or eyes wash skin immediately with a mild soap Flush eyes with water immediately and see a doc tor Hydrogen and oxygen gases are produced dur ing normal battery operation or charging Sparks or flame can cause this mixture to ignite and ex plode if they are brought near the battery Sulphuric acid in battery can cause serious burns if spilled on skin or in eyes Flush or wash away immediately with clear water 90 814676R1
375. s in trim system be replaced Inspect trim rod If scraper located in cap has failed to keep rod clean replace scraper Lubricate all O rings using Quicksilver Power Trim and Steering Fluid or ATF Type FA or Dexron Il 5D 20 MID SECTION Motor and Electrical Tests Repair Trim Pump Motor Test Do not perform this test near flammables or ex plosives as a spark may occur when making connections 1 Disconnect green motor wire and blue motor wire from trim system wiring harness 2 Connect a 12 volt power supply to motor wires positive to blue negative to green results in mo tor up direction Positive to green negative to blue results in motor down direction Motor should run 3 If motor does not run disassemble motor and check components Armature Tests TEST FOR SHORTS Check armature on a Growler follow Growler man ufacturer s test instructions Indication of a short re quires replacement of armature TEST FOR GROUND Use an Ohmmeter R x 1 scale Place one lead on Ohmmeter on armature shaft and other lead on com mutator as shown If continuity is indicated armature is grounded and must be replaced 90 814676R1 DECEMBER 1996 CHECKING AND CLEANING COMMUTATOR If commutator a is worn it can be turned down on an armature conditioner tool or on a lathe pe Sq Clean commutator with 00 sandpaper BM SY Power Trim System Reassembly
376. siphon Valves following See Checking for restricted Fuel Flow caused by Anti Siphon Valves page 3A 4 3 12 FUEL SYSTEM AND CARBURETION Problem Engine Floods Possible Cause Corrective Action Dirt or foreign particles Flush out inlet seat and are preventing inlet clean inlet needle needle from seating Incorrect float setting Reset float Problem Engine Runs Too Lean Possible Cause Corrective Action Carburetor is loose Air Tighten bolts securely leaks past mixing cham Tighten cover or replace ber cover gasket Fuel level too low Reset float level Clogged high speed jet Check and clean Restricted fuel flow to car Check fuel lines and fil buretor ter s for restricted flow Incorrect high speed jet refer to main jet chart and replace with proper jet Idle mixture set too lean Adjust to run richer Air leakage into fuel sys Check fuel line connec tem tions hose clamps fuel pump and fuel outlet tube located in fuel tank for loose fittings Anti siphon valve restrict Refer to Checking for ing fuel flow stricted fuel flow caused by Anti siphon Problem Engine Runs Too Rich Possible Cause Corrective Action Fuel level too high Reset float to correct lev el Carburetor floods See preceding Engine Floods Idle nozzle air holes Blow out with compressed plugged air Restricted air flow Check cowl air inlet and carburetor for obs
377. sition indicates debris or defective compo nents in trim valve assembly Clean or replace components as required 5 Check manual release valve for broken stem and one O ring remaining in the release valve pas sage Separate the manifold assembly from the cylinder to dislodge broken stem Install new re lease valve and test system 6 Check for nicked deteriorated or misplaced O rings throughout trim system 5B 12 MID SECTION Leak Down Check Pump and Manifold Assembly NOTE Scribe d pump housing halves before disas sembly 1 Debris or chips between valve and seat a Usu ally imbedded in rubber valve seat Nicked or deteriorated O ring b Nicked deteriorated or misplaced O ring be tween manifold and trim cylinder Refer to ifold Removal for O ring location 51735 4 After reassembly insert driveshaft and check pump rotation resistance to turning housing halves can shift turn during reassembly Align scribe marks d carefully 90 814676R1 DECEMBER 1996 PAS Leak Down Check Pilot Valve Assembly 1 Debris or chips between check ball and seat a usually imbedded in rubber valve seat 2 Nicked or deteriorated O ring b A leak path is created between the UP side of the cyl inder and the reservoir The trim system will leak DOWN until the trim port in cylinder is covered a Check Ball and Seat b O ring Leak Down Check Manual Release Valve Debr
378. stem with Cil Quicksilver 2 Cycle Outboard Oil is recommended for this oil injection system In an emergency when 2 Cycle Outboard Oil is not available substitute a high quality 2 cycle oil that is intended for outboard use and meet BIA ratings TC W or TC WII shown on oil container BIA ratings TC W and TC WII are the Boating Industry Association s designation for approved 2 cycle water cooled outboard oils Remove fill cap from the oil tank and fill tank with oil Retighten the fill cap e 50330 a Fill Cap 90 814676R1 DECEMBER 1996 Bleeding Air from Injection System CAUTION If air exists in either oil pump hose inlet or out let the air MUST BE bled from the hose s or en gine damage may occur BLEEDING AIR FROM OIL PUMP INLET HOSE 1 With engine not running place a shop towel be low the oil pump Loosen bleed screw three to fourturns and allow oil to flow from bleed hole un til no air bubbles are present in inlet hose Torque bleed screw to 25 lb in 2 8 N m This procedure also allows oil pump to fill with oil BLEEDING AIR FROM OIL PUMP OUTLET HOSE 1 Purge air from outlet hose by running engine on 50 1 gasoline oil mixture in fuel tank at idle speed until no air bubbles are present in outlet hose a Bleed Screw b Inlet Hose C Outlet Hose OIL INJECTION SYSTEM 8 5 Operation of the Injection System 1 Ch
379. ston Exit Shop Rag 90 814676R1 DECEMBER 1996 2 Remove o ring from memory piston a O Ring b Memory Piston 51144 MID SECTION 5E 33 Cleaning Inspection Repair IMPORTANT Components must be dirt and lint free Slightest amount of debris in Power Trim system could cause system to malfunction Clean shock rod and components with parts cleaner and dry with compressed air It is recommended that all O rings in trim system be replaced Use O Ring Kit 25 827668 1 Lubricate all o rings with Quicksilver Power Trim Fluid 92 90100A12 If not available use automo tive ATF automatic transmission fluid Trim Motor Electrical Tests 1 Connecta 12 volt supply to motor leads If motor fails to run replace pump motor IMPORTANT Trim Motor is not serviceable If mo tor fails to run replace motor assembly 5 34 MID SECTION 90 814676R1 DECEMBER 1996 c n Reassembly O Ring and Seal Placement O Rings and Seals are part of O Ring Kit 25 809880A1 90 814676R1 DECEMBER 1996 MID SECTION 5E 35 O ring Sizes e 12 17 15 20 10 O 11 O RINGS SHOWN ARE ACTUAL SIZE 5E 36 MID SECTION 90 814676R1 DECEMBER 1996 Q O ring Description and Sizes O Ring Description O Ring OD Co meen UU 2 evi Cap ner 557r 704mm 0349 E 3 oom Bn 200r BOOM
380. t When Down Circuit Is OK Remote Control NOT Equipped with Trailer Button Connect Voltmeter red lead to Point 8 and black lead to ground Depress the trim button Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to Connect Voltmeter red lead to Point 3 Point 7 and black lead to ground Depress Down trim button If bat tery voltage is indicated wire is open between Points 7 and 8 Battery Voltage Indicated No Voltage Indicated Connect Voltmeter red lead to There is an open circuit between Point 6 Point 3 and positive battery ter Depress Up trim button minal Checkforloose or corroded con nections Check wires for open circuit Battery Voltage Indicated No Voltage Indicated e Pump motor wiring is defective Relay Switch is defective e Pump motor is defective No Voltage Indicated Connect Voltmeter red lead to Point 5 If battery voltage is indi cated trim switch is faulty If no bat tery voltage check for loose or cor roded connection at Point 5 or open circuit in wire supplying cur rent to Point 5 90 814676R1 DECEMBER 1996 MID SECTION 5B 19 p Troubleshooting Down and Up Circuits All Circuits Inoperative Remote Control Not Equipped with Trailer Button Blown Fuse Correct problem that caused fuse to blow Replace fuse No Voltage Indicated Check battery leads for poor connections
381. t bolt and without the bolt adjusted in the proper holes to prevent unsafe handling characteristics Water test the boat not using the trim adjustment bolt If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment bolt in proper hole to prevent unsafe han dling characteristics 52029 a Trim Adjustment Bolt 90 814676R1 DECEMBER 1996 Power System Components Tilt Trim Cylinder Reservoir Motor Housing Piston Rod Upper Pivot Shaft Cross Pin O ring End Cap Seal End Cap O ring O ring Piston Assembly O ring O ring Memory Piston 15 Lower Pivot Shaft 16 Cross Pin 17 Screw 2 18 Pump Assembly 19 Pilot Valve Assembly 20 O ring 21 Driveshaft 22 Washer 4 23 Screw 4 24 Fill Screw 25 O ring 26 Motor Frame 27 Thrust Washer 2 28 Armature 29 Ring 30 Seal 31 Screw 2 32 Screw 4 33 Relay 34 Wiring Harness 35 Relay Mount 2 36 Rubber Mount 2 37 Screw 2 38 Spacer 2 39 Anode 40 Washer 2 41 Screw 2 42 Manual Release Valve ao 43 O ring 44 E clip 51498 NOTE Lubricate all O rings and seals with Quicksilver Lubricants Torque Specifications and Service Aids 100 Ib in 11 1 Loctite 271 92 32609 1 9 13 Ib in 1 5 70 Ib in 7 7 Liquid Neoprene
382. t pin 51144 a Lower Pivot Pin 5E 28 MID SECTION Power Trim Disassembly IMPORTANT Power trim system is pressurized Trim rod must be in the full UP position fully extended prior to fill drain plug or manual re lease valve removal 1 Remove reservoir cap 2 Remove manual release valve assembly to drain oil 55263 a Reservoir Cap b Manual Release Valve 90 814676R1 DECEMBER 1996 Trim Motor Removal 1 Secure power trim assembly in a soft jaw vise 2 Remove four 4 screws to remove motor reser voir Remove reservoir seal and coupler E CL 8 Screw 4 b Reservoir Reservoir Seal d Coupler e Manifold Assembly 90 814676R1 DECEMBER 1996 Pump and Components Removal 1 Remove pressure operated plugs on pump Re move spring and check valve poppet both sides Use specialtool CG 41 11 and special tool CG 41 14 with 5 16 end to remove spool Plug 2 Spring 2 Check Valve Poppet 2 Seat 2 Spool IMPORTANT Inspect poppet assembly for debris in the area shown If debris is found on poppet replace poppet a Debris Under Valve Tip b Rubber Seat MID SECTION 5E 29 2 Remove three 3 screws to remove pump Re move filter and filter seal under pump Remove suction seat assembly Screws 3 Filter Seal Filter
383. t ratio oil pump and provides a mixture of 50 1 90 814676R1 DECEMBER 1996 Check Valve Vent Provides air to oil reservoir for proper venting of reservoir Check valve prevents oil from leaking out of reservoir where outboard is tilted forward 2 PSI Check Valve This valve prevents gasoline from being forced into the oil line Low Oil Float Sensor When oil level in oil reservoir drops until approxi mately 7 5 fl oz 225ml remains the sensor will signal the warning module to activate the warning horn Warning Module When ignition key is initially turned on warning module will briefly provide a self test of its engine overheat warning system a brief steady BEEP tone followed by a self test of its low oil warning System a brief BEEP BEEP tone If the oil level in the oil reservoir drops to less than 7 5fl oz 225ml the low oil float sensor in the oil reservoir will signal the warning module to acti vate the warning horn If the powerhead tempera ture should exceed 300 F 65 C the overheat temperature sensor in the water jacket cover will signal the warning module to activate the warning horn OIL INJECTION SYSTEM 8 1 Oil Injection System WARNING MODULE VENT 3 EIN FUEL FILTER OIL LEVEL OIL SIGHT TANK GAUGE FUEL PUMP 2 BLU o 8 0 FUEL LINE CONNECTOR zr le 2 5 VALVE 50444 8 2 OIL INJECTION SYS
384. t upper pivot pin 51144 a Pivot Pin 90 814676R1 DECEMBER 1996 5 Use suitable punch to remove DRIVE UP lower dowel pin Retain dowel pin a Dowel Pin 6 Use suitable punch to drive out lower pivot pin a Pivot Pin MID SECTION 5C 21 7 Tilt power trim assembly top first out from clamp bracket and remove assembly 5C 22 MID SECTION Power System Disassembly Trim Rod Removal CAUTION DO NOT ADJUST OR REMOVE REVERSE THRUST VALVE THIS VALVE IS PRESET AT FAC TORY FOR PRECISE REVERSE THRUST PRES SURE AND DOES NOT REQUIRE ADJUSTMENT 1 Secure power trim assembly in soft jawed vise 2 Open manual release valve three or four turns counterclockwise and position trim rod to full up position 3 Remove cylinder end cap assembly from cylinder using trim cylinder spanner wrench 1 4 in x 5 16 in long pegs 51194 Manual Release Valve Manifold Reverse Thrust Valve Do Not Remove or Adjust 90 814676R1 DECEMBER 1996 p 4 Remove trim rod assembly from cylinder 51196 5 Remove memory piston from cylinder using lock ring pliers Craftsman P N 4735 or suitable tool 51193 90 814676R1 DECEMBER 1996 6 Remove O ring from memory piston 51196 O ring b Memory Piston 7 Remove trim system from vise and empty fluid into appropriate container Trim Rod Disassembly 1 Place trim rod assembly on clean work surfa
385. tall crankshaft protector cap onto end of crankshaft be fore threading flywheel puller into flywheel Do not strike flywheel puller bolt with hammer as crankshaft may be damaged CAUTION Do not apply heat to flywheel or strike flywheel with hammer as flywheel or electrical compo nents under flywheel may be damaged D 2 2 2 KU JA EN PATH 54642 a Flywheel b Flywheel Puller 91 73687A1 c Crankshaft Protector Cap Hidden Place on end of Crankshaft 90 814676R1 DECEMBER 1996 Flywheel Installation A CAUTION Inspect magnet side of flywheel for any debris clinging to magnets Installing flywheel with de bris on magnets will cause damage to flywheel and or electrical components located under fly wheel when outboard is initially started 1 Secure flywheel on crankshaft with flat washer and nut 2 Onelectric start type flywheel use flywheel hold er 91 52344 to hold flywheel while tightening flywheel nut On manual start type flywheel use strap wrench to hold flywheel while tightening fly wheel nut Torque flywheel nut to 75 Ib ft 101 7 N m Reinstall rewind starter if manual start or fly wheel cover if electric start with 3 bolts Torque bolts to 100 Ib in 11 3 Ignition Components CAUTION To prevent accidental starting of outboard while removing or installing engine components on electric start models remove engine batte
386. tallation 5D 21 Trim Motor Reassembly 5D 22 Reservoir Installation 5D 23 Trim Rod Reassembly 5D 24 Trim Rod Installation 5D 25 Purging Power Trim Unit 5D 26 Power Trim Unit Installation 5D 26 90 814676R1 DECEMBER 1996 A 1 Special Tools Description 91 63209 Spanner Wrench 91 74951 Multi Meter DVA Tester 91 99750 Quicksilver Lubricants and Service Aids Description Power Trim and Steering Fluid 91 9010012 Loctite 271 91 32609 1 Liquid Neoprene 91 25711 1 Anti Corrosion Grease 91 78376A6 Power Trim General Information Description The Power Trim system consists of an electric motor pressurized fluid reservoir pump and trim cylinder The remote control or trim panel is equipped with a switch that is usedfortrimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running Trimming Characteristics When trimming outboard from a mid trim position trim tab in neutral straight fore and aft position you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at
387. tboard to full up position Engage tilt lock level a Trim system fluid can only be checked when outboard is in this position 50157 2 Remove fill screw and check fluid level Fluid lev el should be to bottom of threads in fill hole b 3 If necessary add Quicksilver Power Trim 8 Steering Fluid or Automatic Transmission Fluid ATF Type F FA or Dexron 11 fluid to trim system 4 Reinstall fill screw 90 814676R1 DECEMBER 1996 Trimming Models with Power Trim NOTE Because varying hull designs react differently in various degrees of rough water it is recommended to experiment with trim positions to determine wheth er trimming up or down will improve the ride in rough water When trimming your outboard from a mid trim posi tion trim tab in neutral straight fore and aft position you can expect the following results Trimming Outboard Out Up Characteristics Excessive trim out also may reduce the stabil ity of some high speed hulls To correct instabili at high speed reduce the power GRADUALLY and trim the outboard In slightly before resum ing high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instability 1 Will lift bow of boat generally increasing top speed 2 Transfers steering torque harder to left on stan dard or slightly elevated transom installation single outboard
388. tched ends of the retaining ring must straddle this vent hole O rings Retaining Ring Spring Seal Retaining Ring Outer Seal LOWER UNIT 6B 13 Installing Upper Seals 1 Install spiral retaining ring into the inner ring groove of the upper seal housing Spread a film of grease around the inside bore of the seal surface before pressing in the seals Press in the garter spring seal against the inner retaining ring Fill the garter spring cavity in the seal with grease Install spiral retaining ring into the outer ring groove Align the notched ends of the retaining ring to straddle the small vent hole drilled in the ring groove Press in the outer seal against the retaining ring Grease all the seal lips Grease the two O ring seals and install them into the outer ring grooves IMPORTANT The notched ends of the retaining ring must straddle this vent hole Retaining Ring Spring Seal Retaining Ring Outer Seal O rings 6B 14 LOWER UNIT ax i Installing Drive Shaft Ball Bearing 1 If removed install the bearing thrust ring into the groove on the drive shaft Install collar onto the drive shaft Press the new ball bearing onto the drive shaft pressing against the inner race only Press collar over the thrust ring locking it in its groove Install snap ring into drive shaft groove below the bearing Install
389. te Control Power Trim Tilt Electric Start with Warning Horn Wiring Diagram BLK 4 TAN BLU 3 TAN BLU C GRY YEL BLK 6 PUR 2 BLK 0 PUR BRN WHT BLK YEL 1 YEL RED 7 gt 4 i Up 2 5 e TS ss 0 BLK Black Blue NN 5 BRN Brown 1 GRY Gray N GRNe Green NN N Purple KAS C Red p TAN Tan wd WHT White YEL Yellow Ignition Choke Switch Emergency Stop Switch Neutral Start Switch Tachometer Accessories Harness Connector 23891 Wiring Harness Connector Warning Horn Trim Tilt Switch 5B 16 MID SECTION 90 814676R1 DECEMBER 1996 p i Power Trim System Wiring Diagram a IN i 4 V b Black 1 BLU Blue 111250 9 GRN e Green 1 RED Red Lf F WHT White O9 6 seti M NM b X a 2 8 rt 9 amp i A 1 J WA S f 9 4 eX z d GRNIWHT GRNIWHT 1 Of BLU WHT O Lo lo GRNIWHT BLUIWHT RED PUR 50285 a To Power Trim Pump Motor b Relay Switch UP c Relay Switch
390. te Master gasket Sealant on cylinder block a Oylinder Block b Loctite Master Gasket Sealant 92 12564 1 Apply in a Continuous 1 16 1 6 Bead 14 Place crankcase cover without lateral move ment on cylinder block and secure with mount ing bolts and lockwashers Use torquing se quence shown Torque bolts evenly to 210 Ib in 23 7 N m in 3 progressive steps L t X or OOH 2900 O x p i 50545 Torque Sequence Intake Manifold 90 814676R1 DECEMBER 1996 15 Install centermain bearing and reed block mount ing bolts with locking tabs Torque bolts to speci fied torque and bend locking tabs up and against flat of each bolt 54732 a Reed Block Mounting Bolts 5 8 16mm Long Torque to 75 Ib in 8 5 N m b Centermain Mounting Bolt 1 25mm Long Torque to 75 Ib in 8 5 N m Locking Tab Washers Bend as Shown 16 Secure end caps to cylinder block Torque bolts to specified torque Rotate crankshaft several times to assure free operation no binds and or catches a Torque Bolts to 200 Ib in 22 6 N m b Upper End Cap POWERHEAD 4 43 54683 Torque Bolts to 200 Ib in 22 6 N m b Bottom End Cap 17 Install exhaust cover and divider plate with new gaskets Apply Loctite Grade 271 to bolt threads Torque bolts eve
391. teel Ball c Plunger d O ring 90 814676R1 DECEMBER 1996 Shock Rod Removal 1 Unscrew cylinder end cap assembly using span ner wrench 1 4 in x 5 16 in long pegs 51145 2 Remove shock rod assembly from cylinder MID SECTION 5G 19 Shock Rod Disassembly NOTE The only serviceable items on the shock rod assembly are the O rings and wiper ring If shock rod requires any other repair replace shock rod assem bly 7 b me a a End Cap b O rings 2 c Wiper Ring 1 Place shock rod assembly on clean work surface 2 Remove three 3 screws and remove plate from shock rod piston 51143 a Screw 3 b Plate Shock Rod Piston 5G 20 MID SECTION 3 Remove check ball components from shock rod piston 4 Remove O ring 51147 Springs 5 Seats 5 Balls 5 O ring 90 814676R1 DECEMBER 1996 cM A CAUTION When removing shock piston spanner wrench must have 1 4 in x 5 16 in long pegs to avoid damage to shock piston 5 90 814676 1 Place shock rod in soft jawed vise and apply heat to loosen piston using torch lamp P N 91 63209 Loosen shock rod piston using spanner wrench 1 4 in x 5 16 in 6 4mm x 8mm long pegs Allow shock rod piston to cool Remove from shock rod 51146 Spanner Wrench Shock Rod Piston Inspect check valve for debris clean debris from check va
392. ters to BLUE and BLUE WHITE terminals on switch box Torque terminal nuts to 30 Ib in 3 5 N m Install cap nuts on unused terminals BLUE Cable Adapter b BLUE WHITE Cable Adapter c Cap Nuts 24 18 ELECTRICAL AND IGNITION 90 814676R1 DECEMBER 1996 i Electric Models Secure adapter module and wir ing with sta straps Sta Straps b Adapter Module Hidden c Adapter Module WHITE GREEN Lead d Adapter Module GREEN WHITE Lead e Stator YELLOW Leads f Caps g Adapter Module BLUE Lead h Adapter Module BLUE WHITE Lead i Adapter Module BLACK Lead Torque bolt to 40 Ib in 4 5 N m 90 814676R1 DECEMBER 1996 54957 ELECTRICAL AND IGNITION 24 19 Manual Models Secure adapter module and wiring with sta straps 54955 Sta Straps Adapter Module Insulator Plug Stator BLUE WHITE
393. th Quicksilver 2 4 C Marine Lubricant fea M s m H TAM H n HU 7224 ZZ 22252 N 4 Ride Guide Cable Ride Guide Yoke Pivot Block Pivot Spacer 15 in Centerline of Attaching Kit Pivot to Centerline of Outboard Pivot Attaching Locknut Torque to 20 Ib ft 27 1 N m Outboard Steering Arm Clevis Kit Ride Guide Cable Attaching Locknut Torque to 10 Ib ft 13 6 N m Bolt 3 8 in x 2 1 2 in Flat Washer Transom Bracket Figure 1 Installing Attaching Kit 3 90 814676R1 Place Ride Guide yoke on pivot block and secure with 7 16 in x 1 3 4 in bolt and locknut as shown in Figures 1 and 2 Torque locknut to 10 Ib ft 13 6 N m then back off 1 4 turn Install one cable tube jam nut onto steering cable tube Place tab washer over Ride Guide yoke then insert cable tube thru tab washer and yoke Install second cable tube jam nut onto cable tube but do not tighten at this time Figure 3 Position transom attaching kit on transom as fol lows a Determine centerline of outboard then mea sure 15 in 38 1cm over from this centerline and draw a vertical line on transom Figure 1 DECEMBER 1996 2 3 Place pivot block on pivot spacer and secure to transom bracket with 3 8 in x 2 1 2 in bolt flat washer and locknut as shown in Figure 1 Torque
394. that harness will not interfere with en gine throttle and shift operation OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7A 21 Power Trim Wiring Connections Models So Equipped Make bullet connector wiring connection between remote control wiring harness key switch wiring har ness and engine wiring IMPORTANT Tape back and isolate any unused wiring harness leads Ne Lie b al Ji 1 E ERN jo M Up Relay Switch Down Relay Switch Starter Solenoid Trim Switch From Control Harness 22 OUTBOARD MOTOR INSTALLATION ATTACHMENTS c Battery Connections CAUTION Failure to observe correct polarity when con necting battery cables to battery will result in damage to the charging system 1 Connect battery cables from engine to battery Connect red battery cable to positive battery terminal and black battery cable to negative battery terminal tc 2 a BLUIWHT BLU ce BLU GRNI Je 20 BLK Black 50285 BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 90 814676R1 DECEMBER 1996 PAS t Connecting Remote Control Stop Switch Wiring to Engine Wiring Manual Start Models 1 Locate the engine mounted stop switc
395. the Cowl Switch does op erate Trim Switch and Cowl Switch are both inoperative Trim system operates motor runs without pressing the switches 5E 26 MID SECTION 1 Open wire between Wire Connection 1 and Trim Switch 2 Faulty Trim Switch 1 Open wire between Wire Connection 2 and Solenoid 2 Faulty Cowl Switch 1 Open wire between Wire Connection 1 and the Up Relay 2 Open BLK wire between ground and UP Relay 3 Open RED wire between Solenoid and Up Relay 4 Faulty Up Relay 1 Open wire between Wire Connection 3 and Trim Switch 2 Faulty Trim Switch 1 Open wire between Wire Connection 2 and Solenoid 2 Faulty Cowl Switch 1 Open wire between Wire Connection 3 and the Up Relay 2 Open BLK wire between ground and Down Relay 3 Open RED wire between Solenoid and Down Relay 4 Faulty Down Relay 1 20 AMP Fuse blown 2 Faulty trim switch 3 Wire is open between fuse holder and solenoid 4 Wire is open between fuse holder and trim switch 1 One of the Trim Pump Motor wires is open between the motor and the Relays 2 Faulty trim pump motor 1 The Trim or Cowl switch is shorted 1 Check for an open connection or cut wire 2 Replace 1 Check for an open connection or cut wire 2 Replace 1 Check for an open connection 2 Check for an open connection 3 Check for an open connection 4 Replace 1 Check for an open connection or cut wire 2
396. the desired trim angle within the 20 maximum trim range The Power Trim system is designed so the en gine cannot be trimmed beyond the 20 maximum trim angle as long as engine RPM is above approxi mately 2000 RPM The engine can be raised beyond the 20 maximum trim angle for shallow water operation etc by keep ing the engine RPM below 2000 RPM If engine RPM increases above 2000 RPM the thrust created by the propeller if deep enough in the water will cause the trim system to automatically lower the engine back to the 20 maximum trim angle TRIMMING OUTBOARD DOWN IN Excessive speed at minimum trim In may cause undesirable and or unsafe steering condi tions Each boat should be tested for handling characteristics after any adjustment is made to the tilt angle tilt pin relocation Will help planing off particularly with a heavy load Usually improves ride in choppy water In excess can cause boat to veer to the left or right bow steer Transfers steering torque harder to right or less to the left Improves planing speed acceleration by moving tilt pin one hole closer to transom Operating Down circuit will actuate the down sole noid located under engine cowl and close the elec tric motor circuit motor will run in opposite direction of the Up circuit The electric motor will drive the pump thus forcing automatic fluid thru internal pas sageways into the down side of the t
397. through center opening in rubber grommet b 4 Position barrel receptacle a into receptacle guide b 54835 7 Apply a drop of Loctite 271 onto exposed threads of throttle cable barrel set screw DO NOT tight nc MR en set screw at this time A CAUTION DO NOT exceed 1 4 turn on set screw after it has bottomed out 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7B 7 8 With throttle lever held lightly against stop b and throttle twist grip at IDLE turn set screw of throttle cable barrel in until it bottoms out on tube then tighten screw an additional 1 8 turn 54837 10 Check preload on throttle cable by placing a thin piece of paper between idle stop screw and idle stop Preload is correct when paper can be re moved without tearing but has some drag on it Readjust throttle cable barrel if necessary 7B 8 OUTBOARD MOTOR INSTALLATION ATTACHMENTS c Lanyard Stop Switch Wiring 1 Route Lanyard Stop Switch and Neutral Start Switch wiring through bushing as shown Secure wiring to tiller bracket a using sta strap b BN 54838 2 Remove electrical box side cover c
398. through trim ram until pivot pin is flushed with swivel bracket a Pivot Pin b Swivel Bracket C Trim Ram 5C 38 MID SECTION c 8 Drive upper dowel pin a into its hole until seated 9 Recheck fluid level 10 Power trim may now be operated to lower out board to desired position Trim system is self bleeding 51147 11 Re connect spark plug leads to spark plugs 12 Re install top cowl 13 Connect battery leads to battery terminals 90 814676R1 DECEMBER 1996 MID SECTION POWER TRIM DESIGN 3 Table of Contents Page Special Tools 5D 1 Power Trim General Information 5D 1 Description 5D 1 Trimming Characteristics 5D 1 Trimming Outboard Up Out 5D 1 Trimming Outboard Down 5D 1 Trailering Outboard 5D 2 Tilting Outboard Up and Down Manually 50 2 Trim Angle Adjustment 5D 2 Power Trim System Components 5D 3 Troubleshooting 5D 4 Determining if Problem is Electrical or Hydraulic 50 4 Hydraulic System Troubleshooting 5D 5 Preliminary Checks 5D 5 Leak Down Check Pump and Manifold Assembly 50 5 Leak Down Check Pilot Valve Assembly 5D 6 Leak Down Check Manual Release
399. thrust Test ing complete 5E 22 MID SECTION 90 814676R1 DECEMBER 1996 Hydraulic System Troubleshooting Flow Chart TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED Manual release valve and O rings appear to be O K Clean and reinstall manual release valve Manual release valve and O ring damaged Inspect manual release valve Trim system leaks down Remove tilt relief valving and inspect O rings and Replace manual re Trim system does not leak down Test ing complete lease valve and O rings Trim system does not leak down seals for debris and or Testing complete damage Tilt relief valving and O rings appear to be O K Clean and Debris and or dam age identified Replace tilt relief valving Trim system does not leak down Test ing complete Debris and or dam age identified Replace PO check valve assembly Trim system does not leak down Test ing complete 90 814676R1 DECEMBER 1996 reinstall tilt relief valving Trim system does not leak down Test ing complete Trim system leaks down Remove PO check valve assembly inspect O rings and seals for damage PO check valve appears O K Clean and reinstall PO check valve assembly Trim system does not leak down Test ing complete Trim system leaks down continued on next page MID SECTION 5E 23 Hydraulic System Troubleshooting Flow Chart continued Inspect memory pis ton O
400. tle Pick Up Screw Top Carburetor 2C 2 ELECTRICAL AND IGNITION 4 While holding throttle spark arm against IDLE RPM SCREW STOP rotate actuator plate until PRIMARY THROTTLE CAM just touches PRI MARY PICK UP ARM on carburetor cluster Re tighten actuator plate retaining screws Primary Cam Primary Pick Up Arm Just Touching Secondary Lever 90 814676R1 DECEMBER 1996 MAXIMUM TIMING ADJUSTMENT Advance throttle spark arm until MAXIMUM SPARK ADVANCE SCREW is against stop En gage electric starter If necessary adjust maxi mum spark advance screw to align 32 BTDC mark on flywheel with V notch in timing pointer window Tighten locknut WA 54662 a Maximum Spark Advance Screw b Stop Locknut IMPORTANT The advance characteristics of this ignition system are such that the ignition timing will retard itself slightly at wide open throttle Thus setting maximum timing at 32 BTDC at cranking speed should result in retardation to 30 BTDC at 5500 RPM Therefore it is recom mended that to be assured of maximum perfor mance from this outboard all timing adjust ments made at cranking speed should be verified with the outboard running 2 Remove timing light and SPARK GAP TESTER from 1 TOP spark plug lead 3 Reinstall spark plugs Torque spark plugs to 20 Ib ft 27 1 N m 4 Reconnectspa
401. to the reservoir by the ball inside the up circuit suction port i Oil under pressure opens the down pressure operated valve f and enters the down passages inside of the man ifold q The manifold passage connects into the trim cylinder passage leading to the top of the cylinder The cavity inside the cylinder above the shock pis ton u is the down cavity As the down cavity fills with oil the piston rod a retracts into the cylinder lower ing the outboard motor Oil from the up cavity exits in the cylinder and is drawn back into the pump through the open up pressure operated valve n When the piston rod reaches full travel the oil pressure inside the down circuit will rise until the down pressure relief valve e opens bypassing oil back into the reservoir When the trim button is released and the oil pump stops supplying pressure both of the pressure oper ated valves f amp n will close and if open the down pressure regulating valve e will close The closed valves will lock the fluid on either side of the shock piston u amp memory piston t holding the outboard motor in position 90 814676R1 DECEMBER 1996 MID SECTION 5E 13 cM SHOCK FUNCTION UP Reservoir Return zi w L Oil Under Pressure PA Impa
402. trim panel is equipped with a switch that is used for trimming the outboard up and down and for tilting the outboard for shallow water operation at slow speed or for trailering The out board can be trimmed up or down while engine is under power or when engine is not running Trimming Characteristics NOTE Because varying hull designs react differently in various degrees of rough water it is recommended to experiment with trim positions to determine wheth er trimming or down will improve the ride in rough water When trimming your outboard from a mid trim posi tion trim tab in neutral straight fore and aft posi tion you can expect the following results TRIMMING OUTBOARD UP OUT Excessive trim out may reduce the stability of some high speed hulls To correct instability at high speed reduce the power gradually and trim the motor In slightly before resuming high speed operation Rapid reduction in power will cause a sudden change of steering torque and may cause additional momentary boat instabili ty Will lift bow of boat generally increasing top speed Transfers steering torque harder to left on installa tions below 23 in transom height Increases clearance over submerged objects In excess can cause porpoising and or ventilation In excess can cause insufficient water supply to wa ter pump resulting in serious water pump and or pow erhead overheating dama
403. truc tions Main fuel jet loose Retighten jet 90 814676R1 DECEMBER 1996 Fuel tank air vent closed Check Air vent must be or restricted open all the way and free from restrictions A pinched cut or re Check all fuel lines and stricted fuel line also replace as needed Check loose fuel line connection and tighten all fuel line connections A dirty or restricted fuel fil Check replace or clean ter all fuel filters Restricted filter in fuel Clean by rinsing in clean tank lead free gasoline or kero sene Improperly mixed fuel Check fuel and replace if contaminants water dirt necessary etc in fuel An inlet needle in carbu and replace with retor that is either stuck new inlet needle open or closed A needle that is stuck open will cause a flooding condi tion A needle that is stuck closed will prevent fuel from entering carburetor Incorrect idle mixture ad Readjust justment Damaged fuel pump dia Replace phragm Carburetor is loose Tighten bolts securely Chamber cover leaking Tighten or replace gasket air Off idle holes plugged Blow out with compressed air Main nozzle or idle nozzle Blow out with compressed air bleed holes plugged air Improper main jet or re Clean or replace with stricted jet proper jet refer to Main Jet Chart Damaged reed s Inspect reeds as outlined in Section 4A A crack in the fuel pickup Replac
404. ts of the following parts 1 Battery 2 Starter motor solenoid 3 Neutral start switch 4 Starter motor 5 Ignition switch Description The function ofthe starting system is to crank the out board The battery supplies electrical energy to crank the starter motor When the ignition switch is turned to Start position the starter solenoid is activated and completes the starter circuit between the battery and starter The neutral start switch opens the starter circuit when the shift control lever is not in neutral This prevents accidental starting when engine is in gear CAUTION The starter motor may be damaged seriously if operated continuously DO NOT operate continu ously for more than 30 seconds Allow a 2 minute cooling period between starting attempts BATTERY FUSE HOLDER IF EQUIPPED 20 AMP FUSE Starter Circuit 2B 8 ELECTRICAL AND IGNITION Pg PN y RENT eA gd 87 09 c n Troubleshooting the Starter Circuit Before beginning the starter circuit troubleshooting flowchart following check first for the following conditions 1 Make sure that battery is fully charged 2 Check that shift control lever is in neutral posi tion 3 Checkterminals for corrosion and loose connec tions 4 Check cables and wiring for frayed or worn in sulation 5 Checkfuse in red wire The following Starter Circuit Troubleshooting Flow Chart is designed as an aid to troub
405. tween valve and seat a usu ally imbedded in rubber valve seat 2 Pilot valve installed from non chamfered end of spool results in nicked or damaged O ring b 3 Nicked or deteriorated O ring c A leak path is created between the UP side of the cyl inder and the reservoir The trim system will leak DOWN until the trim port in cylinder is covered a Valve and Seat b Pilot Valve O ring c O ring Leak Down Check Manual Release Valve 1 Debris or chips under O ring a 2 Flash from valve molding causing O ring a to not seal 3 Nicked O ring a 51560 a O ring 90 814676R1 DECEMBER 1996 Leakage Past Ball and Seat Piston Assembly Unit will trim to full or near full DOWN position and then will begin to trim UP while trim switch is held in DOWN mode If trim switch is released outboard can be pushed by hand DOWN to the point where trim UP started 1 Inspect balls and seats in piston assembly for de bris or damage Repair or replace balls seats a Ball and Seat Check for Debris or Damage MID SECTION 5C 13 Troubleshooting Flow Diagram Outboard falls to full down position with manu al release valve closed Example a Outboard lowers more than one tilt pin hole in eight hours Example b Outboard lowers during acceler ation Inspect Manual Release Valve Result Result Manual release valve and or O Manual release valve and O rings ring damage appear
406. uld be avoided Test run the boat If cavitation occurs air enters the pump causing loss of thrust engine over speeds erratically the first thing to try is lowering the outboard height 1 4 in This can be accomplished by elongating the drilled mounting holes in the boat transom by 1 4 in If cavitation still exists after lowering the outboard 1 4 in it maybe helpful to seek advice from the boat manufacturer A number of other options are available to further re duce cavitation 1 Water intake fin kit Available from the Specialty Mfg Co for jet models 30 thru 140 The purpose of these fins is to ram more water into the intake and shield the forward sides of the intake from the entrance of air This kit will help reduce cavitation when running with the wind in a chop 5 Fasten outboard to the transom at this height Water testing Checking for Cavitation Making the initial outboard height setting should be close to the optimum setting for the outboard Howev er because of the hull design of some boats obstruc tions or imperfections in the hull ahead of the water in take may require this setting to change in order to prevent cavitation at running speeds 6B 6 LOWER UNIT a Intake Fin Kit Water Intake Fin Kit Part No 1186 for jet models 45 thru 140 and Part No 1185 for jet model 30 is available from Specialty Mfg Co 2035 Edison Ave San Leandro CA 94577 90 814676R1 DECEMBER 1996 cM
407. using water intake holes whenever engine is running While operating up circuit the ram will continue to tilt outboard to full up position for trailering Tilting Outboard Up and Down Manually Before opening the manual release valve make sure all persons are clear of engine as engine will drop to full down position when valve is opened With power trim installed the outboard can be raised or lowered manually by opening the manual release valve 3 turns maximum counterclockwise a Manual Release Valve 5D 2 MID SECTION c Trim Angle Adjustment Operating some boats with engine trimmed to the full trim angle not using trim adjustment bolt a at planing speed will cause undesirable and or unsafe steering conditions Each boat must be water tested for handling characteristics after engine installation and after any trim adjust ments IMPORTANT Some boat motor combinations that do not use the trim adjustment bolt a and are trimmed to the full trim angle will not ex perience any undesirable and or unsafe steering conditions during planing speed Thus not us ing trim adjustment bolt may be desired Howev er some boats with engine trimmed to the full in trim angle at planing speed will cause unde sirable and or unsafe steering conditions If these steering conditions are experienced un der no circumstances should the engine be oper ated without the trim adjustmen
408. ustment pin If undesirable and or unsafe steering conditions are experienced boat runs with nose down install trim adjustment pin in proper hole to prevent unsafe han dling characteristics 50157 1 4 IMPORTANT INFORMATION Power Trim System Models with Power Trim General Information The power trim system is filled at the manufacturer and is ready for use Trim outboard through entire trailering range several times to remove any air from the system The trim system is pressurized and is not externally vented The outboard can be raised or lowered manually by loosening the manual release valve 2 to 3 turns coun terclockwise The trim out angle of this outboard is not adjustable The trim system has an internal valve which will auto matically stop the outward trim travel at 200 when en gine RPM is approximately 2000 RPM or higher out board also has to be in water and in gear The outboard can be operated beyond the 200 trim limit for operating outboard in shallow water if engine RPM is kept below approximately 2000 RPM 50146 a Fill Screw System is Pressurized DO NOT Open Unless Outboard is Tilted to Full Up Position b Manual Tilt Release Valve Location 90 814676R1 DECEMBER 1996 cM Checking Trim System Fluid Level IMPORTANT This trim system is pressurized Remove fill screw when outboard is trimmed to the full up position Retighten fill screw secure ly 1 Trim ou
409. ut of sleeve sleeve and washers will hold needle bearings in position in connecting rod 5 Place piston on connecting rod Position piston pin bore directly over sleeve and slide piston pin tool thru upper pin bore and into sleeve IMPORTANT Intake side of piston deflector must face towards intake ports 6 Lubricate piston pin with light oil Use a mallet and drive piston pin into piston while maintaining the position of piston pin tool with other hand Contin ue to drive pin into piston as tool and sleeve are driven out 54718 a Install Piston so that Deflector will be Toward Intake Ports b Piston Pin Tool C Piston Pin POWERHEAD 4 35 7 Secure piston pin in piston by installing new 9 Lubricate rings with light oil and align ring ends type piston lockrings into groove in each end of with locating pins in ring grooves piston pin bore Make sure that lockrings are seated in grooves a Piston Ring Locating Pin 54697 a Piston Pin Lockring One Each Side b Needle Nose Pliers 8 Install new piston rings on piston with Piston Ring Expander Tool 91 24697 Spread each ring just enough to slip over piston Check that piston rings rotate freely in ring grooves If ring does not rotate freely condition must be corrected Design 2 4 36 POWERHEAD 90 814676R1 DECEMBER 1996 Crankshaft Seal Installation SEAL CARRIER REPLACEMENT DESIGN 1 N
410. ve fuel inlet hose and outlet hose 52014 52025 90 814676R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 5 p i 4 Remove gasket from powerhead Fuel Pump Disassembly 1 Remove bolts and chamber plate 52019 a Bolts a Gasket b Chamber Plate 2 Disassemble fuel pump as shown in Fuel Pump Exploded View 3 6 FUEL SYSTEM AND CARBURETION 90 814676R1 DECEMBER 1996 Fuel Pump Exploded View Design 1 IMPORTANT Align all gasket and diaphragm aligning tabs with fuel pump aligning tabs during reassembly NOTE Respective diaphragms go against the mat ing surfaces of the fuel pump body and respective gaskets are between the diaphragms and end caps Gaskets should always be replaced on fuel pump reassembly REVERSE ANGLE REVERSE ANGLE Fuel Pump Body Rubber Check Valve Plastic Disc Retainer Spring Cap Diaphragm Boost Chamber Gasket Chamber Plate 10 Pulse Chamber Gasket 11 Fuel Pump Base 50569 12 Base Gasket 90 814676R1 DECEMBER 1996 FUEL SYSTEM AND CARBURETION 3 7 Cleaning and Inspection 1 Clean fuel pump housing chamber plate and pump base then dry with compressed air Inspect spring coils for damage Inspect pump body chamber plate and pump base for cracks or rough gasket surfaces Inspect hoses for looseness or signs of leakage 5 Inspect check valve discs for cracks tears or oth er damage Chec
411. ver possible Where the fasteners are not satisfactory for re use care should be taken to select a replacement that matches the original Cleanliness and Care of Outboard Motor A marine power product is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in the ten thousands of an inch mm When any product component is serv iced care and cleanliness are important Throughout this manual it should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure This is considered standard shop practice even if not specif ically stated Whenever components are removed for service they should be retained in order At the time of instal lation they should be installed in the same locations and with the same mating surfaces as when re moved Personnel should not work on or under an outboard which is suspended Outboards should be attached to work stands or lowered to ground as soon as pos sible We reserve the right to make changes to this manual without prior notification Refer to dealer service bulletins for other pertinent in formation concerning the products described in this manual 90 814676R1 gt 1996 IMPORTANT INFORMATION GENERAL INFORMATION and SPECIFICATIONS Table of Contents Page Propeller Information 1 1 How to Use this
412. vers fuel to the engine thru fittings located on each carburetor flange Equal fuel amounts are delivered while depressing primer bulb with engine stopped or running 3 18 FUEL SYSTEM AND CARBURETION Enrichener Valve Manual Operation IMPORTANT Use of enrichener if motor is warm could result in engine flooding Squeeze primer bulb until bulb is firm Press button in on enrichener valve and hold approximately 5 sec onds Release button Start outboard 52014 a Button 90 814676R1 DECEMBER 1996 Enrichment Valve Test Push key or choke but ton in Valve should click No Click Click Check for battery voltage to yellow black wire at termi Squeeze primer bulb until bulb is firm Remove lower hose nal block on engine when key or choke button is from fitting on enrichener valve Place a container under pushed in valve then push key or choke button Check for fuel flow from fitting Battery Voltage Indicated Check for loose or corroded connection between yellow black wire and black wire under same screw at terminal block No Voltage Indicated Check that other black wire at terminal block is properly grounded Check for open circuit in yellow black wire between key switch or choke button and terminal block Repair connections s as necessary then push key or choke button in If enrichener valve DOES NOT click re place valve Fuel Flow from Fitting Valve is O K Check hoses and fittings from
413. vidu al spark plug lead should be grounded to engine Before troubleshooting the ignition system check the following a Make sure that electrical harness lanyard switch ignition switch and mercury switch are not the source of the problem b Check that plug in connectors are fully en gaged and terminals are free of corrosion c Make sure that wire connections are tight and free of corrosion d Check all electrical components that are grounded directly to engine and all ground wires to see thatthey are grounded to engine e Check for disconnected wires and short and open circuits Checking for Loss of Spark The use of an inductive timing light while cranking or running the engine will show whether there is spark present or not The timing light will not show the strength of the spark Incorrect spark strength may not allow the spark plug to fire under compression The use of a spark gap or spark gap board will give a visual indication of the strength of the spark Nor mal ignition spark is BLUE in color A YELLOW or RED spark indicates a weak ignition 2 2 ELECTRICAL AND IGNITION Troubleshooting Test Equipment Multimeter DVA Tester 91 99750 Spark Tester 91 850439 W AN 92 2 STS BS alle ecc 90 814676R1 DECEMBER 1996 T Ignition Troubleshooting Engines With Black Stator Troub
414. xit the vent hose Reconnect the vent hose onto the grease fitting after greasing After 30 hours of operation pump in extra grease to purge out any moisture Visually inspecting the purged grease at this time will give you an indication of conditions inside the bearing housing A gradual in crease in moisture content indicates seal wear If the grease begins to turn dark or dirty gray the drive shaft bearing and seals should be inspected and replaced if necessary Some discoloration of the grease is nor mal during the break in period on a new set of seals 6B 8 LOWER UNIT 2 Impeller Removal and Installation REMOVAL 1 Shift outboard to NEUTRAL N position 2 Remove spark plug leads to prevent engine from starting 3 Remove the water intake housing that is fastened with six screws 4 Straightenthe benttabs on the impeller nut retain er and remove the impeller nut 5 Pull impeller straight off the shaft If the impeller is tight use a hammer and block of wood to rotate the impeller clockwise on the shaft until the key way is directly above the flat on the shaft This will free the jammed key and allow removal Tab Nut 90 814676R1 DECEMBER 1996 x f INSTALLATION 3 After setting the impeller height tighten the impel ler nut snug with a wrench Secure impeller nut by 1 i Grease the drive shan Shear key and bending tabs against the flats on the impelle
415. y not be possible to steer the outboard in an emergency a Friction Device Position so Wing Nut b will be Positioned Toward Front of Outboard b Wing Nut Pivot Rod d Link Rod e Spacer Hidden Place in Hole f Flat Washer g Locknut Torque to 120 Ib in 13 6 N m h Locknut Tighten Until it Seats DO NOT Exceed 120 Ib in 13 6 N m then Back Off 1 4 Turn 90 814676R1 DECEMBER 1996 26381 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7B 11 cM Shift Interlock Adjustment 3 Interlock actuator b must align with rise of inter lock cam c while shift lever is in the neutral posi MANUAL START MODEL tion CAUTION 4 Tighten cable attaching screw securely DO NOT shift into R reverse gear position when engine is not running as shifting mecha nism could be damaged 1 Shift outboard into neutral position 2 Loosen cable attaching screw a to allow cable movement b Interlock Actuator Interlock Cam 7B 12 OUTBOARD MOTOR INSTALLATION ATTACHMENTS 90 814676R1 DECEMBER 1996 OUTBOARD MOTOR INSTALLATION ATTACHMENTS REWIND STARTER Table of Contents Page Rewind Starter Components 7C 1 Torque Specifications 7C 1 Quicksilver Lubricants and Service Aids 7C 1 Rewind Starter Disassembly 7C 2 Cleaning

Service Manual Outline

Contents

Download Pdf Manuals

Related Search

Related Contents